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This application claims Paris convention priority of GB 1122446.6 filed Dec. 29, 2011 the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Dynamic nuclear polarization is a technique which has attracted increasing interest in recent years. Methods for dynamic nuclear polarization are described, for example, in WO-A-1999/035508, WO-A-2002/037132, and WO-A-2011/026103, the contents of which are incorporated herein by reference. The essence of the technique is to carry out a magnetic resonance investigation on a nuclear spin system (typically 13 C or 15 N) of which the spin polarization levels have been perturbed from their equilibrium values prior to a nuclear magnetic resonance investigation, and thereby enhance the sensitivity of the investigation. The perturbation of the spin polarization levels is achieved by interaction between an electron spin resonance transition and a nuclear spin system.
In the DNP experiment described in WO-A-1999/035508, a hyperpolarized solution of a high T 1 agent is produced by dissolving a hyperpolarized solid sample of the high T 1 agent in a physiologically tolerable solvent. The hyperpolarization of the solid sample is effected by means of a polarizing agent, which may be at least partially separated from the high T 1 agent after use. The sample is then administered, for example by injection, to a patient, and is then irradiated using a second rf to excite nuclear spin transitions in selected nuclei e.g. the MR imaging nuclei of the high T 1 agent. Magnetic resonance signals are detected and NMR spectral data, an image, dynamic flow data, diffusion data, perfusion data, physiological data may be measured. The long T 1 results in persistence of the nuclear spin polarization, allowing significantly enhanced sensitivity in the NMR determination to be achieved over a useful time period.
One disadvantage of this approach is the relatively long polarization time (typically of the order of thirty minutes or more).
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method for producing a hyperpolarized sample material for use in an NMR investigation, comprising:—
(a) providing a cryogenic region; (b) providing a target material containing a first hyperpolarizable nuclear species, a second hyperpolarizable nuclear species, and a nuclear spin polarizing agent in the first cryogenic region, wherein the first hyperpolarizable nuclear species has a higher magnetic moment (γ), than the second hyperpolarizable nuclear species; (c) supplying microwave energy to the first cryogenic region to excite electron spin transitions in the polarizing agent in the presence of a magnetic field (B 0 ), (d) causing the first hyperpolarizable nuclear species to interact with the electron spin system in the polarizing agent thereby generating hyperpolarization of at least the said first nuclear species of the target material; and (e) subjecting the target material to a lowered magnetic field, wherein the lowered magnetic field is such as to facilitate polarization transfer by means of nuclear thermal mixing between the first hyperpolarizable nuclear species and the second hyperpolarizable nuclear species, thereby to effect hyperpolarization of the second nuclear species. The first hyperpolarizable nuclear species, having a higher magnetic moment (γ) than the second hyperpolarizable nuclear species is preferably present in greater abundance than the second hyperpolarizable nuclear species.
The invention also provides apparatus for producing a hyperpolarized sample material for use in an NMR investigation, comprising:—
a first cryogenic region; means for locating a target material containing a first hyperpolarizable nuclear species and a second hyperpolarizable nuclear species, and a nuclear spin polarizing agent in the first cryogenic region; a first magnet, for generating a magnetic field (B 0 ) in the first cryogenic region; means for supplying microwave energy to the first cryogenic region to excite an electron spin state of the target material in the presence of the magnetic field (B 0 ), and thereby hyperpolarizing at least the said first nuclear species;
and
a second magnet, spaced from the first magnet, and having a magnetic field opposed to the field produced by the first magnet, thereby to produce a region of approximately zero magnetic field in a second region, lying between the first cryogenic region and the second magnet; and means for moving the target material from the first cryogenic region through the second region, thereby to facilitate transfer of nuclear polarization from the first hyperpolarizable nuclear species to the second hyperpolarizable nuclear species.
In a particularly preferred embodiment, the first, hyperpolarizable nuclear species is 1 H. The low γ/long T 1 nuclear species may be, for example 19 F, 6 Li, 13 C, 15 N, 29 Si, 89 Y, or 31 P. 13 C and 15 N are particularly preferred.
The use of a relatively high γ/short T 1 nuclear spin such as as as the initial polarization target, followed by polarization transfer to the low γ/long T 1 nuclear spin can be achieved, in accordance with the invention, by nuclear thermal mixing (i.e. thermal mixing between two nuclear species) at low field whereby the two nuclear species reach a common spin temperature (A. Abragam, The Principles of Nuclear Magnetism , Clarendon Press, Oxford, 1960). Other methods are known for effecting polarization transfer between two species, for example by the application of appropriate RF pulses to the two spin systems, (e.g. Hartmann-Hahn matched spin-lock pulses or other cross polarization pulse sequences) at constant B 0 (S. R. Hartmann, E. L. Hahn, Phys. Rev. 128, 2042 (1962)). Although such methods may be effective in a less technically challenging environment, the application of a sufficiently strong RF field at two frequencies in a cryogenic region necessitates the use of more complex instrumentation (Sami Jannin, Aurélien Bornet, Sonia Colombo, and Geoffrey Bodenhausen, Chem. Phys. Lett., (2011) (doi.org/10.1016/j.cplett.2011.10.042).
In accordance with the invention therefore, the magnetic field to which the target material is subjected is lowered, in order to facilitate equilibration of the spin temperatures of the two species. In a first embodiment of the invention, the magnetic field to which the target material is subjected is lowered by actually lowering the B 0 field to a suitable low value. In practice, rapidly switching the field of a high power superconducting magnet is very difficult to achieve. In a much preferred embodiment of the invention therefore, the magnetic field to which the target material is subjected is lowered by physically moving the target material from the first (B 0 ) region, to a second region, in which the magnetic field is sufficiently low to effect nuclear thermal mixing, i.e. sufficiently low for the Zeeman energy of the two nuclear species to be of comparable or smaller magnitude than their dipolar coupling energy. This condition will be met in most practical situations if the field strength is of the order of 100 μT or less (note that the earth's magnetic field is in the order of 30-60 μT). For convenience in the following discussion, the second region in which the field is sufficiently low to effect nuclear thermal mixing is referred to as a “mixing field” region.
The provision of the “mixing field” region may be achieved by providing a second magnet, having a magnetic field which is opposed in direction to the field direction of the magnet which provides the B 0 field, so that a region of low or zero field (not substantially different from the earth's magnetic field) results between the first and second magnet.
Previous work in this area, in particular in the references discussed above, suggests that bulk polarization is lost rapidly if the sample (either in the solid or in the liquid state) traverses a field of zero or very low field. The present invention is based on the realization that the polarization loss observed in dissolution DNP when a sample traverses a region of zero field, is likely to be caused by thermal mixing. When low abundant low γ (long T 1 ) spins are hyperpolarized by DNP, and their spin temperature is allowed to equilibrate with abundant proton spins at thermal equilibrium by nuclear thermal mixing at low field, the spin temperature of the long T 1 nucleus will be greatly increased, and thereby the hyperpolarization of the long T 1 spins is lost.
In accordance with the method of this invention, initial dynamic nuclear polarization of high γ (short T 1 ) nuclear spin species (typically 1 H) is initially carried out, followed by subjecting the target (comprising the high γ/short T 1 nuclear spins and the low γ/long T 1 nuclear spins) to a period at low or zero field, thereby hyperpolarizing the low γ/long T 1 nuclear spin species (typically 13 C or 15 N) by equilibration of the spin temperatures of the two species. Polarization of the high γ nuclear spins is possible in a significantly shorter time that is required for the long T 1 nuclei, thereby significantly increasing the speed of the polarization process.
In a preferred embodiment, the low-gamma nuclei may be also be subjected to some polarization by DNP at the same time as the high gamma nuclei are polarized (by the selection of two different microwave frequencies for excitation). This dual excitation can enhance the overall polarization level.
In an alternative embodiment, a polarizing agent may be selected that has a relatively broad electron resonance peak, such as 2,2,6,6,tetramethylpiperidine-1-oxyl (“Tempo”), that can simultaneously polarize both nuclear spin species.
Once the highly polarized sample material has been formed in the solid state, a solution may be formed, by dissolving the material containing the second, long T 1 , hyperpolarizable nuclear spin species (referred to herein as the “long T 1 agent”), in a suitable solvent, with or without separation from the target material, in the manner disclosed generally in WO-A-1999/035508. Typically, an injectable solution may be formulated from the hyperpolarized second nuclear species, which can be injected directly into an animal (for example a patient) prior to carrying out a nuclear magnetic resonance investigation, at enhanced signal levels. The long T 1 agent should therefore be capable of being provided in a form in which it is physiologically tolerable, and easily administered. The long T 1 agent is preferably soluble in aqueous media (e.g. water) and is physiologically non-toxic.
The long T 1 agent should be such that it remains polarized for a period sufficiently long to allow an imaging or other MR investigation to be carried out. This can generally be achieved if the material has a T 1 value (at a field strength of 0.01-5T and a temperature in the range 20-40° C.) of at least 5s, more preferably at least 10s, especially preferably 30s or longer, more especially preferably 70s or more, yet more especially preferably 100s or more (for example at 37° C. in water at 1T and a concentration of at least 1 mM).
13 C is particularly suitable for use as the second hyperpolarizable nuclear species, for the reasons discussed in WO-A-1999/035508
In a further preferred embodiment, steps (c) to (e) above may be repeated one or more times (i.e., the polarization and nuclear thermal mixing steps may be cycled) so as to increase the polarization effect.
The principle of DNP Using nuclear thermal mixing may be illustrated by the following specific example. The thermal equilibrium polarization of a spin ½ nuclear species S in a strong magnetic field can be described by the following expression:
P S = tanh ( Δ E S 2 kT ) ( 1 )
in which ΔE S is the Zeeman energy of the nuclear species S, k Boltzmann's constant, and T the lattice temperature. If the polarization of the nuclear spin species has been enhanced by means of hyperpolarization, then the non-equilibrium polarization level P* S can be characterized by defining a “spin temperature” T S different from the lattice temperature T by:
P
S
*
=
tanh
(
Δ
E
S
2
kT
S
)
(
2
)
Consider now two nuclear species exposed to a strong magnetic field whereby one is hyperpolarized, i.e. its spin temperature is substantially lower than the lattice temperature. If the field is adiabatically reduced to a very small value, i.e. a value where the Zeeman energy of the two nuclear species is comparable or smaller than their dipolar interaction energy, then the two spin baths will reach a common spin temperature. When, subsequently, the field is again increased to the original value, then the common spin temperature with reference to the high field is given by:
1 T = 1 / T ′ + μ / T ″ 1 + μ ( 3 )
in which T′ and T″ are the initial spin temperatures of the two nuclear species and T is the common spin temperature. With N the number of spins and γ the gyromagnetic ratio, then for spins ½ the constant μ is defined as:
μ
=
γ
″
2
N
″
γ
′
2
N
′
(
4
)
For example in a molecule with one 13 C nucleus and ten protons, if the carbon has been hyperpolarized to e.g. 30% (corresponding to a spin temperature of 3 mK @ 3.35T) and equilibrates with protons with the proton spin temperature equal to the lattice temperature of, say, 1.5 K, then the equilibrium spin temperature will be about 350 mK, which corresponds to a carbon polarization of approximately 0.25%. It can be seen therefore that more than 99% of the original polarization is lost.
By contrast, if protons are polarized to a spin temperature of 3 mK @ 3.35T, which can be achieved in a relatively short time (typically a few minutes) and in that short time polarization of 13 C is also built up to, say, 5% (corresponding to ˜20 mK), then the equilibrium spin temperature after nuclear thermal mixing at low field would be slightly higher than 3 mK. The carbon polarization would therefore be enhanced to approximately 25%.
Re-distribution of the polarization in nuclear thermal mixing takes place amongst all the nuclei in the sample. In order to obtain maximum enhancement of the 13 C polarization, it is therefore not only advantageous to maximize the number of protons such as to benefit from a larger bath of cold spins according to expression (4), but also to restrict the number of other nuclei in the sample. As a consequence it is preferred to use protonated, rather than deuterated solvents. (It is common practice in dissolution DNP to use deuterated solvents).
Simultaneous DNP of protons and carbon can be accomplished by choosing a suitable radical for interaction with the nuclear spins, or by modulation of the microwave frequency such as to give power bands at the appropriate frequencies for protons and carbon DNP.
Radicals suitable for use in DNP are generally known in the art. Examples of suitable free radical are: (2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (“TEMPO”) or derivatives such as 4-amino-TEMPO (as described in WO-A-1999/035508) and Triarylmethyl and related radicals such as tryphenylmethyl (Trityl) (as described in WO-A-2006011811).
Targets well known in the art are intermediates in metabolic cycles, for example fumaric acid and pyruvic acid as preferred contrast agents for the imaging of metabolic activity. Other possible agents suitable for hyperpolarization and subsequent use as MR contrast agents are non-endogenous and endogenous compounds such as acetates, pyruvates, oxalates or gluconates, sugars, (such as glucose or fructose), urea, amides, amino acids (for example glutamate, glycine, cysteine or aspartate), nucleotides, vitamins (for example ascorbic acid), penicillin derivates and sulfonamides. Similarly suitable substances are the so-called “neurochemical agents” described in WO 2011024156, and the materials described in US-A-20110008261. Many other substances can be advantageously hyperpolarized and used according to the invention.
The mechanism of transferring polarization from proton to carbon by nuclear thermal mixing has been demonstrated in a brute force hyperpolarization field cycling experiment. In this experiment nuclear thermal mixing was shown to be effective in transferring polarization from 1 H to 13 C during the ramping of the magnetic field from −3.4T to +3.4T. (D. G. Gadian, Poster abstract 579, Joint Euromar 2010 and 17 th ISMAR Conference, Florence, 2010)
The sample can be exposed to the mixing field by expelling it from the polarizer magnet by means of fluid pressure, for example by means of compressed helium gas, as proposed in WO2011/026103.
Alternatively a field cycling polarizer magnet can be used. The latter has the advantage that the polarization transfer step can be repeated, to bring the carbon spin temperature even closer to that of the protons.
A number of preferred embodiments of the invention will now be described with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a first embodiment of the invention, with the target material positioned in a magnetic field B 0 ;
FIG. 2 shows the apparatus of FIG. 1 with the target material elevated so that it is positioned in the field of a second magnet;
FIG. 3 is a schematic representation of a second embodiment of the invention, with the target in a lowered position in a cryostat;
FIG. 4 shows the apparatus of FIG. 3 , with the sample in a raised position; and
FIGS. 5 and 6 illustrate a preferred embodiment of the device according to the invention, having a sample movement device using fluid (He gas) to move the sample between magnets.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 , The device comprises a high field superconductive polarization magnet ( 2 ) inside a cryostat ( 1 ). The field strength is usually at least 1 T and may be as high as current technology permits, which currently is of the order of 20 T. Field strengths of 3.35 T or 6.7 T, may be particularly convenient, because they permit the use of microwave apparatus for excitation which is readily commercially available. Higher field strengths such as for instance 9.4 T or higher may afford higher levels of polarization. This higher level of polarization comes in general at the price of much slower polarization build-up due to the higher values of the T 1 relaxation times at high field. The substantial reduction in polarization build-up time for the long T 1 nuclear spin species in accordance with the present invention mitigates this problem and allows DNP hyperpolarization with an acceptable polarization build-up time even at high field.
A low temperature cryostat ( 3 ) is located inside the magnet. The cryostat is preferably of a type which can reach a temperature of as low as 1.5 K, or down to 1 K. Lower temperatures enable higher levels of polarization to be achieved, but give rise to significantly increased complexity (and therefore cost) in the design of the cryostat. In particular, temperatures below 4.2 K require the use of helium evaporation techniques which necessitates the use of pumping equipment and may result in the cryostat operating at sub-atmospheric pressure. In situations in which a sufficient level of polarization can be achieved without the need for temperatures below 4.2K therefore, there may be significant commercial advantage in operating at a temperature of 4.2K.
In a particular embodiment, a lambda point refrigerator may be used in which a two phase system is created, with the upper phase at 4.2K, and the lower phase at the lambda point of helium, i.e. at 2.2K. The pumping requirement for such a cryostat is modest and the design allows operation at atmospheric pressure. Such a cryostat offers a commercial advantage over a 1.5K cryostat while limiting the loss of polarization compared to a 4.2K cryostat.
A movable sample positioning device ( 5 ) with attached sample holder ( 4 ) is used to position the sample inside the cryostat ( 3 ) by means for instance of a pneumatic actuator or electro-mechanical drive (not shown) for polarization of the nuclear spins. This is shown as position (A) in FIG. 1 . The sample positioning device ( 5 ) comprises a microwave guide coupling the sample holder ( 4 ) to a microwave source (not shown), for exciting electron spin-spin transitions of a species present in the target to enhance the nuclear spin polarization by means of DNP.
The sample, such as for example sodium acetate, in which the acetate is 13 C labeled, is subjected to DNP hyperpolarization in a manner to ensure maximum increase of the polarization of the short T 1 nuclear spins, i.e. the protons. It is advantageous to ensure that also the long T 1 ( 13 C) nuclear spin polarization is enhanced simultaneously by judicious choice of a broad line free radical such as for instance TEMPO. Alternatively, when using a narrow line free radical such as Trityl, the 13 C nuclei may be partly pre-polarized by employing appropriate modulation of the microwave radiation if desired, whereby microwave power bands simultaneously are provided at distances from the electron Larmor frequency corresponding to the proton and carbon Larmor frequencies.
The DNP process may be terminated as soon as the 1 H nuclei have reached a desired level of polarization. The polarization level of the 1 H nuclei is preferably at least 40% and may be as high as 100%, but is typically in the range 40-90%, more usually 50-80%. At this time, the 13 C nuclei will have become only partially polarized.
The device further comprises an auxiliary low field magnet ( 6 ) which is located above the polarization magnet ( 2 ) and has variable field strength which can be regulated from 0 mT up to 10 mT or more. The field strength in the auxiliary magnet ( 6 ) should be sufficiently high to avoid loss of polarization due to longitudinal relaxation. It should be noted that the longitudinal relaxation time T 1 at very low magnetic field can be very short. The polarity of the low field magnet ( 6 ) is opposite to that of the polarization magnet ( 2 ) such that between the two magnets a region exists where the fields cancel and the residual magnetic field is very low, for example less than 100 μT (i.e. approximately the same as the value of the earth's magnetic field).
Magnetic shielding (not shown) may be provided between the two magnets to shield the earth's magnetic field and thereby reduce the field strength in the low field region even further, to below 10 μT or below 1 μT or lower. One example of a magnetic shielding device is a tube of ferromagnetic material but other magnetic shielding devices known in the art may be equally effective.
An auxiliary cryostat ( 7 ) is positioned inside the auxiliary magnet ( 6 ). The temperature of the auxiliary cryostat ( 7 ) can be regulated, for example to a temperature down to 4.2 K or lower, and, in some embodiments, down to 1.5 K or even down to 1 K, and up to room temperature. Alternatively a dual region cryostat may be used, as described below with reference to FIGS. 3 and 4 .
After polarization, the sample in sample holder ( 4 ) is moved rapidly (i.e., generally in a time of less than 1 second) from the main cryostat ( 3 ) into the auxiliary cryostat ( 7 ), located in auxiliary magnet ( 6 ), by means of the sample positioning device ( 5 ). FIG. 2 shows the sample positioning device ( 5 ) in its upper position (B). As the sample traverses the region of low or zero field between polarization magnet 2 and auxiliary magnet 6 , the polarization of the abundant 1 H nuclei, (which have short T 1 /high γ) is partially transferred to 13 C nuclei (which have long T 1 /low γ) by means of low field nuclear thermal mixing. The polarization of the 13 C nuclei is thereby enhanced.
The speed of transfer through the region of low field must be chosen judiciously so as to be sufficiently fast to avoid loss of polarization in either nuclear spin, whilst sufficiently slow to allow polarization to be transferred effectively from the short T 1 to long T 1 nuclei. The time needed for a particular experimental arrangement will vary depending on the sample type, field strength, and geometry of the apparatus, an can be determined by experiment for the particular arrangement. In general, it is found that the sample positioning device should be such that it is possible to move the sample from position (A) to position (B) in a time of 1 second or shorter, preferably 100 ms or shorter, and more preferably down to approximately 10 ms. It is generally desirable that the time spent by the sample in the mixing field region (i.e., the region in which the field strength is 100 μT or less) is 100 ms or less, more preferably 20 ms or less, even more preferably 5 ms or less.
In a preferred embodiment, said sample positioning device ( 5 ) is controlled by an electro-mechanical drive (for example a belt driven by a stepper motor), which can be programmed to move the sample at variable speed, thereby ensuring the shortest possible time is spent moving the sample from position (A) to the mixing field region and from the mixing field region to position (B) whereas, at the same time, the time spent travelling through the mixing field region is long enough to effectuate efficient polarization transfer through nuclear thermal mixing.
The magnetic field strength in the auxiliary magnet ( 6 ) and the temperature of the auxiliary cryostat ( 7 ) may be chosen such as to obtain conditions of long T 1 for the low γ 13 C nucleus. During or after transfer from the polarization cryostat ( 3 ) to the auxiliary cryostat ( 7 ) an optional heating element in sample holder ( 4 ) may be employed to rapidly bring the sample to the temperature of the auxiliary cryostat ( 7 ).
The effect of nuclear thermal mixing is that the short T 1 1 H spins are brought into thermal contact with the long T 1 13 C spins so that the two spin baths reach a common spin temperature. As a consequence the spin temperature of the long T 1 nuclei is lowered, leading to the desirable enhancement in polarization. The spin temperature of the 1 H nuclei is increased and polarization of these nuclei is reduced. If the original difference in spin temperatures of the two spin baths was large, it may be that after nuclear thermal mixing, the long T 1 nucleus has not yet reached an optimum level of polarization.
In a particularly preferred embodiment, the temperatures in the polarization cryostat ( 3 ) and the auxiliary cryostat ( 7 ) (or in the two cryogenic regions of a dual region cryostat) are substantially the same. In that case, the sample does not experience significant temperature change during the polarization transfer, and can therefore be returned to the polarization region (position (A)) for a “top-up” of the polarization level of the 1 H nuclei, followed by a further cycle of nuclear thermal mixing. The sample polarization level for the 13 C nuclei can thereby be further enhanced. This process can be repeated two or more times, as desired, in order to further increase the polarization level. A dual region cryostat as discussed in more detail below is particularly suitable for this purpose.
When the frozen sample has reached the auxiliary magnet ( 6 ) after the final polarization cycle, it can be rapidly dissolved or melted by means of solvent conduits in the sample positioning device ( 5 ) or the heating element in sample holder ( 4 ), or by other means, and used to formulate an injectable solution, for use in an NMR or MRI experiment.
An alternative embodiment of the apparatus is shown in FIG. 3 and FIG. 4 , which utilizes two coupled regions of cryogenic temperature, between which a sample can be rapidly moved.
A first region of cryogenic temperature of about 1 K can easily be created inside a bath of liquid helium which is subjected to a pressure much lower than atmospheric pressure. This principle is described, in for example, WO-A-2006106285 (Oxford Instruments Molecular Biotools). A further example is described in “ A. Comment et al.”, Conc. Magn. Res. 31(B), 255, 2007. This arrangement is usually referred to as an “immersion cryostat” and in practice restricts access for loading/unloading a sample to the top part of the cryostat. If access from both ends of the cryostat is required, e.g. to load a sample from the top of the cryostat to the cryogenic region and then unloading it by moving it further down such as to exit from the bottom, or vice versa, then instead of an immersion cryostat a flow cryostat can be employed. An example of such a flow cryostat is described in EP-A-2028505 (Oxford Instruments Molecular Biotools; Nottingham University)
The device shown in FIG. 3 and FIG. 4 utilizes both of these principles in a single device, which is capable of generating two coupled regions of cryogenic temperature.
As is customary in cryogenic practice, the device comprises a series of concentric cylinders which form an outer vacuum chamber ( 21 ), in which is placed a heat shield ( 22 ), and which enclose a working volume ( 23 ). A helium vessel ( 24 ) surrounds the enclosure of working volume ( 23 ), inside vacuum chamber ( 21 ). Helium vessel ( 24 ) is connected via conduit ( 25 ) to a supply of liquid helium via a needle valve (not shown). A second conduit ( 26 ) connects helium vessel ( 24 ) to a low capacity pump (not shown) to enable vessel ( 24 ) to be filled with liquid helium.
A further, capillary, conduit ( 27 ) connects helium vessel ( 24 ) to a position close to the bottom of working volume ( 23 ) enabling the lower part of the working volume to be filled with liquid helium, thereby forming the immersion volume ( 28 ). The working volume is connected to a high capacity pump (not shown) via conduit ( 29 ) to allow the pressure in the working volume to be reduced, thereby lowering the temperature of the immersion volume ( 28 ) to a temperature lower than 4.2 K, typically as low as 1.5 K, or even as low as 1 K or lower. Control over the pumping speed and therefore the pressure and temperature can be provided by a butterfly valve or other known means (not shown).
A further capillary conduit ( 30 ) connects helium vessel ( 24 ) to a second cryogenic region ( 32 ) higher up in working volume ( 23 ). The capillary conduit ( 30 ) terminates in a spray nozzle ( 31 ) which causes a spray of cryogenic helium to enter the working volume ( 23 ), thereby creating the second cryogenic region ( 32 ) where the temperature will again be below 4.2 K, as low as 1.5 K, or even as low as 1 K or lower.
A sample can be loaded into the device by means of a sample positioning device ( 33 ) which holds a sample holder ( 34 ). The sample positioning device ( 33 ) is introduced into the low pressure working volume ( 23 ) in a generally conventional manner, by means of sliding seals and a load lock (not shown). Movement of the sample is effected by an actuator (not shown) which allows the sample to be moved rapidly between the position shown in FIG. 3 , in which the sample is in the immersion region ( 28 ) and the position shown in FIG. 4 , in which the sample is in the second cryogenic region ( 32 ). Polarization and nuclear thermal mixing is carried out generally by the method described with reference to FIGS. 1 and 2 .
In the embodiment shown in FIGS. 3 and 4 , the two cryogenic regions are closely coupled in temperature by virtue of the pumping of He gas out of the working volume. It is however possible to provide a larger degree of thermal separation between the two regions, thereby allowing the second region to be regulated at temperature that is a much higher temperature than that of the immersion region.
FIGS. 5 and 6 illustrate a preferred embodiment of a device according to the invention, having a sample movement device using fluid (He gas) to move the sample between magnets.
FIGS. 5 and 6 show a device of the type generally described above, and illustrated in FIGS. 1 and 2 . Like reference numbers are used for the same parts as in FIGS. 1 and 2 , and those parts of the device will not be further described in detail.
The devices of FIGS. 5 and 6 differ from those of FIGS. 1 and 2 in that the sample is placed in a self-contained sample holder ( 8 ) within a sample conduit ( 9 ) having a lower sample position (shown in FIG. 5 ) and an upper sample position (shown in FIG. 6 ). The sample conduit is placed inside the cryostat ( 3 ) initially with the sample holder ( 8 ) in the lower sample position, as shown in FIG. 5 , such that it is placed in the center of the polarizer magnet ( 2 ) for DNP of the short T 1 nuclei.
After the DNP process, a pressurized gas (e.g., He) is supplied to a sample propulsion gas inlet ( 10 ). The gas pressure propels the sample holder containing the sample rapidly through a mixing field region to the upper sample position ( 8 , FIG. 6 ) in sample conduit ( 9 ), which places the sample holder in the center of the auxiliary magnet ( 6 ). The transit through the mixing field region subjects the sample to low field nuclear thermal mixing.
The pressurized He gas exits via outlet ( 11 ).
It is to be understood that although the invention has been described with reference to specific embodiments, many other specific arrangements are possible, within the scope of the appended claims.
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A method and apparatus for producing a hyperpolarized sample material for use in an NMR investigation provides for a cryogenic region having a target material containing a first hyperpolarizable nuclear species, a second hyperpolarizable nuclear species, and a nuclear spin polarizing agent, wherein the first nuclear species has a higher magnetic moment than the second nuclear species. Microwave energy is used to excite electron spin transitions in the polarizing agent in the presence of a magnetic field. The first hyperpolarizable nuclear species is thereby caused to interact with the electron spin system in the polarizing agent and generate hyperpolarization of at least the first nuclear species of the target material. The target material is then subjected to a lowered magnetic field, wherein the lowered magnetic field facilitates polarization transfer by nuclear thermal mixing between the species to thereby hyperpolarize the second nuclear species.
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BACKGROUND
[0001] Virtual Private Networks (i.e., VPNs) provide a secured means for transmitting and receiving data between network nodes even though many users share a corresponding physical network supporting propagation of the data. Privacy is maintained through the use of a tunneling technique, such as generic routing encapsulation (GRE). The data transmitted between such network nodes may be encrypted to protect against eavesdropping and tampering by unauthorized parties. Because the physical network is shared, costs of using resources are generally reduced for each of many users.
[0002] A particular type of VPN is known as a Dynamic Multipoint VPN (DMVPN). DMVPN allows users to better scale large and small Internet Protocol Security (IPSec) VPNs by combining Generic Routing Encapsulation (GRE) tunnels, IPSec encryption, and Next Hop Resolution Protocol (NHRP) to provide users with easy configuration.
[0003] IPSec VPNs are built as a collection of point-to-point links. The most efficient way to manage larger and larger collections of these point-to-point links is to arrange them into hub router-and-spoke router networks. All traffic from behind one spoke router (i.e., the traffic from networks that must travel through the spoke router to get to the hub router) to behind another spoke router will need to traverse first to the hub router and then back out to the other spoke router.
[0004] Routers define nodes in a network, and data travels between the nodes in a series of so-called “hops” over the network. Since each router is typically connected to multiple other routers, there may be multiple potential paths between given computers. Typically, the routing information is employed in a routing table in each router, which is used to determine a path to a destination computer or network. The router makes a routing decision, using the routing table, to identify the next “hop,” or next router, to send the data to in order for it to ultimately reach the destination computer.
[0005] In a DMVPN environment, each spoke router has a “permanent” (i.e., always-on) IPSec tunnel to a hub router, but not to the other spoke routers within the network. Each spoke router registers as clients of the NHRP server, which may reside in the hub router. The hub router maintains an NHRP database of the publicly routable address(es) of each spoke router. Each spoke router registers its binding of “publicly routable” address and (private) tunnel address when it boots and becomes capable of querying its NHRP database for the publicly routable addresses of the destination (remote) spoke routers in order to build direct tunnels to the destination spoke routers, when needed.
[0006] When a spoke router needs to send a packet to a destination subnet on another (remote) spoke router, it queries the NHRP server for publicly routable address of the destination (remote) spoke router. The spoke router also obtains the ‘next hop’ for that destination spoke router from the NHRP server. After the originating spoke router learns the peer address of the remote spoke router, it can initiate a dynamic IPSec tunnel to the remote spoke router. The spoke router-to-spoke router tunnels are established on-demand whenever there is traffic between the spoke routers. Thereafter, packets are able to bypass the hub router and use the spoke router-to-spoke router tunnel. Once the transfer is complete, the spoke router-to-spoke router tunnel is torn down.
[0007] DMVPN provides on-demand creation of IPSec encrypted GRE tunnels for direct spoke router-to-spoke router communication and even builds a fully-meshed network, if needed. The spoke router-to-spoke router tunnels are dynamically created based on the interesting traffic from one spoke router site to another spoke router site so as to bypass the Hub router. A spoke router site includes any of the hosts (also referred to as netowkr devices) inside a spoke router of the DMVPN network as well as the spoke router itself.
SUMMARY
[0008] Conventional mechanisms such as those explained above suffer from a variety of deficiencies. One such deficiency is that while conventional DMVPN technology provides an efficient/scalable framework in which the network resources (such as IPSec SAs) are only claimed when needed as each spoke router site dynamically establishes the tunnel to every other spoke router site triggered by the interesting traffic (received internally from the site), it leaves an opportunity in which one infected spoke router site can disrupt the whole DMVPN network. If any of the hosts (collectively with the spoke router referred to as a spoke router site) inside a spoke router of the DMVPN network becomes infected with a worm (such as a polymorphic worm), then the worm could indirectly exploit the dynamic nature of DMVPN to an extent of “melting down” the DMVPN network. In other words, the worm can potentially over-run the maximum number of tunnels that spoke routers can handle and/or bombard the hub router with hundreds of Resolution Requests, resulting in a Distributed Denial of Service (DDOS) attack. In conventional systems there is no efficient mechanism to prevent the DMVPN melt-down, to isolate the worm-infected spoke router site and to restrict the spread of the worm within the DMVPN network.
[0009] Although the mechanisms by which the worm propagates within an enterprise network is well known, its propagation when combined with the dynamic nature of DMVPN results in an undesired effect in which the spoke router site sends Resolution Requests in the order of few tens to few thousands to the hub router site. This could potentially cause the hub router to become unstable and if more than one spoke router site becomes infected, then the hub router will get overwhelmed by so many messages that it would potentially drop the important control plane traffic. The hub router indirectly becomes the DDOS target. Certain polymorphic worms can mount attacks to every possible IP address within an enterprise (public IP address subnet assignment to an enterprise is publicly known) and can melt-down the whole DMVPN Network.
[0010] The present method of preventing infection propagation in a DMVPN isolates the infected spoke router site from the DMVPN network, if needed. This causes the spoke router of the spoke router site having an infected host to (bi-directionally) stop communicating with any network devices (including the hub router, any other spoke routers etc.) within the DMVPN.
[0011] In another embodiment, the present method of preventing infection propagation in a DMVPN isolates the infected spoke router site such that it can only communicate with the hub router, but cannot communicate with any remote spoke router site. This provides the opportunity for the hub router to redirect the received traffic to a Scrubber, if needed to separate out the “good” traffic from the “bad” traffic and forward the good traffic to the relevant destinations.
[0012] In a particular embodiment of a method of preventing infection propagation in a DMVPN the method includes receiving an indication at a hub router that a spoke router site including a spoke router in communication with the hub router has become infected and sending a purge message to the spoke router of the spoke router site, the purge message directing the spoke router to purge at least one NHRP request. The method further includes receiving the purge message at the spoke router, and purging, by the spoke router, cached entries in a forwarding database and refraining from resolving any next-hop requests. The purge request is also sent to other spoke routers, which are part of the DMVPN network, to purge the infected spoke router from their next hop database.
[0013] Other embodiments include a computer readable medium having computer readable code thereon for preventing infection propagation in a DMVPN. The computer readable medium includes instructions for receiving an indication at a hub router that a spoke router site including a spoke router in communication with the hub router has become infected and instructions for sending a purge message to the spoke router, the purge message directing the spoke router to purge at least one NHRP request. The computer readable medium further includes instructions for receiving the purge message at the spoke router and instructions for purging, by the spoke router, cached entries in a forwarding database and refraining from resolving any next-hop requests.
[0014] Still other embodiments include a computerized device, configured to process all the method operations disclosed herein as embodiments of the invention. In such embodiments, the computerized device includes a memory system, a processor, communications interface in an interconnection mechanism connecting these components. The memory system is encoded with a process that provides a method of preventing infection propagation in a DMVPN as explained herein that when performed (e.g. when executing) on the processor, operates as explained herein within the computerized device to perform all of the method embodiments and operations explained herein as embodiments of the invention. Thus any computerized device that performs or is programmed to perform up processing explained herein is an embodiment of the invention.
[0015] Other arrangements of embodiments of the invention that are disclosed herein include software programs to perform the method embodiment steps and operations summarized above and disclosed in detail below. More particularly, a computer program product is one embodiment that has a computer-readable medium including computer program logic encoded thereon that when performed in a computerized device provides associated operations providing a method of preventing infection propagation in a DMVPN as explained herein. The computer program logic, when executed on at least one processor with a computing system, causes the processor to perform the operations (e.g., the methods) indicated herein as embodiments of the invention. Such arrangements of the invention are typically provided as software, code and/or other data structures arranged or encoded on a computer readable medium such as an optical medium (e.g., CD-ROM), floppy or hard disk or other a medium such as firmware or microcode in one or more ROM or RAM or PROM chips or as an Application Specific Integrated Circuit (ASIC) or as downloadable software images in one or more modules, shared libraries, etc. The software or firmware or other such configurations can be installed onto a computerized device to cause one or more processors in the computerized device to perform the techniques explained herein as embodiments of the invention. Software processes that operate in a collection of computerized devices, such as in a group of data communications devices or other entities can also provide the system of the invention. The system of the invention can be distributed between many software processes on several data communications devices, or all processes could run on a small set of dedicated computers, or on one computer alone.
[0016] It is to be understood that the embodiments of the invention can be embodied strictly as a software program, as software and hardware, or as hardware and/or circuitry alone, such as within a data communications device. The features of the invention, as explained herein, may be employed in data communications devices and/or software systems for such devices such as those manufactured by Cisco Systems, Inc. of San Jose, Calif.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0018] FIG. 1 comprises a DMVPN environment wherein infection propagation is prevented in accordance with embodiments of the invention;
[0019] FIGS. 2A and 2B comprise a flow diagram of a particular embodiment of a method of preventing infection propagation in a Dynamic Multipoint Virtual Private Network in accordance with embodiments of the invention; and
[0020] FIG. 3 illustrates an example network device architecture that provides method of preventing infection propagation in a Dynamic Multipoint Virtual Private Network in accordance with embodiments of the invention.
DETAILED DESCRIPTION
[0021] Referring to FIG. 1 , an example of a DMVPN environment 10 is shown. A Hub router 12 , is in communication with a plurality of spoke routers 14 , 16 and 18 . This is accomplished by an IPSec tunnel extending from the hub router 12 to each spoke router 14 , 16 and 18 . A spoke router may be part of a spoke router site which includes the spoke router and other devices (referred to as hosts) in communication with the spoke router. For example, spoke router 14 and PC 28 make up a spoke router site. In this example environment 10 , hub router route 12 has a tunnel 20 to spoke router 14 , a tunnel 22 to spoke router 16 and a tunnel 24 to spoke router 18 .
[0022] In the DMVPN environment 10 , each spoke router ( 14 , 16 and 18 ) has a “permanent” IPSec tunnel to the hub router 12 , but not to the other spoke routers within the network. Each spoke router ( 12 , 14 and 16 ) registers as clients of the NHRP server, which may reside in the hub router 12 . The hub router 12 maintains an NHRP database of the publicly routable address(es) of each spoke router. Each spoke router registers its binding of “publicly routable” address and (private) tunnel address when it boots and becomes capable of querying its NHRP database for the publicly routable addresses of the destination (remote) spoke routers in order to build direct tunnels to the destination spoke routers, when needed.
[0023] When a spoke router needs to send a packet to a destination subnet on another (remote) spoke router, it queries the NHRP server for publicly routable address of the destination (remote) spoke router. The spoke router also obtains the ‘next hop’ for that destination spoke router from the NHRP server. After the originating spoke router learns the peer address of the remote spoke router, it can initiate a dynamic IPSec tunnel to the remote spoke router. The spoke router-to-spoke router tunnels are established on-demand whenever there is traffic between the spoke routers. Thereafter, packets are able to bypass the hub router and use the spoke router-to-spoke router tunnel. An example of this is shown by spoke router-to-spoke router tunnel 26 which has been established between spoke router 14 and spoke router 16 . This may be used for example when a packet received by spoke router router 14 from PC 28 is destined for Internet 30 via spoke router 16 .
[0024] When a spoke router site of a DMVPN becomes infected with a worm, the worm can very quickly propagate by sending traffic to each possible destination within the enterprise network over DMVPN. If the infected host within a spoke router site sends out traffic to destinations residing in remote sites, the spoke routr of the infected spoke router site will, by nature of DMVPN, automatically start setting up the IPSec and GRE tunnels to each remote spoke router site. Of course, to do this, spoke router will have to resolve the unresolved next-hops and hence send out the NHRP resolution request for each of the Next-Hops (DMVPN Phase II) or each of the prefixes (DMVPN Phase III).
[0025] In the event a Worm/DoS attack has been detected through an existing/known mechanism (e.g., by a security monitoring application or other type of mechanism) in a specific DMVPN spoke router site. In this example, spoke router 14 has become infected with a DDOS worm. Once it has been detected that a given spoke router site has one or more infected hosts, then the NHRP hub router 12 will immediately send an NHRP message (a NHRP “Purge All Request” message) to that spoke router. The NHRP Purge All Request message is sent in order to invalidate all the entries in a NHRP cache at the spoke router. Upon receiving such a message, the spoke router will clear at least one of the dynamically learned entries in the NHRP database (leaving only the statically configured NHRP mapping). When a spoke router receives an NHRP Purge All request, it must discard any previously cached information in the NHRP next-hop database.
[0026] This message may also include a NHRP extension “No Resolution Request Until Further Notice”. The NHRP extension “No Resolution Request until Further Notice” conveys to the spoke router that the spoke router can not attempt to resolve any of the Next-hops until further notice. This extension, when combined with the “NHRP Purge All Request”, would convey the receiver of the NHRP message to invalidate/flush all the dynamically learned/cached entries within the NHRP database and do not attempt to send any NHRP Resolution Request for them. Without this extension, the spoke router of the Purge All request” could flush all the entries within the NHRP database and generate NHRP Resolution Request message for each of the next-hops or prefixes.
[0027] Upon receiving the NHRP Purge All Request, the spoke router 14 flushes/invalidates all the cached entries in the NHRP database and will not attempt to resolve any of the next-hop or prefixes until requested by the hub router 12 . This causes the spoke router 14 to use NHS's address to encapsulate all future data packets to divert the traffic to the hub router 12 automatically.
[0028] The spoke router 14 acknowledges the invalidation of the NHRP database by sending the NHRP “Purge All Reply” message to sender (hub router 12 ) of the NHRP Purge All Request message. The NHRP Purge All Reply message mentioned above is sent in order to ensure the sender of the Purge All Request, that all the cached information has been purged by the station sending the Reply. Since the NHRP database entries are already flushed/invalidated, the IPSec SAs associated with these entries will be torn down and will not be used for the direct spoke router-to-spoke router communication. Thus, spoke router-to-spoke router tunnel 26 is torn down.
[0029] It is important that hub router 12 also invalidates the NH information (for the infected spoke router) at all other spoke router's NHRP database. This can be done by letting the hub router 12 also send NHRP Purge Requests to all the spoke routers (e.g. spoke routers 16 and 18 ). The newly defined NHRP Extension “No resolution request until further notice” may also be appended within the NHRP Purge Request to ensure that the remote spoke routers do not attempt to resolve the next-hop belonging to the infected spoke router.
[0030] Other NHC/spoke routers receiving this NHRP Purge Request will discard the previously cached information that matches the information in the CIEs of the Purge Request message. They will also reply with the NHRP Purge Reply to the hub router 12 and do not send the NHRP Resolution Request for the specific address(es) specified within the CIE. This step is required to address the DMVPN_Phase — 2 enhancements in which the spoke router can build the IPSec tunnel based on an NHRP Resume Reply from another spoke router.
[0031] Depending upon whether the hub router 12 has a traffic scrubber available, the Hub router could take either of the following two actions. If the hub router 12 doesn't have any scrubbing functionally for the infected traffic, then the hub router 12 may prefer to altogether avoid receiving the traffic from the infected spoke router site until or unless the spoke router site gets rid of the worm. Alternately, the hub router 12 , upon receiving the traffic from the infected spoke router site, can redirect the traffic to a Scrubber for cleansing of the traffic. One the bad traffic has been separated from the good traffic, then the good traffic can be forwarded towards the relevant spoke routers.
[0032] In a further embodiment, either the NHRP or TRDP trigger could be used by the hub router 12 to send an Access control List (ACL) to the spoke router 14 , which will simply install the ACL on either the outbound tunnel interface or the physical interface. This will cause all the spoke router-to-spoke router traffic to be dropped at the spoke router itself. Optionally, the ACL could be such that even the spoke router-to-Hub router traffic could be dropped, if needed.
[0033] Once it has been determined that the spoke router site is no longer infected (after taking the relevant corrective measures at the spoke router site), the hub router 12 triggers a new NHRP message (a NHRP Resume Resolution Request) requesting the spoke router 14 to start sending the Resolution Requests for the remote Next-hops or prefixes to the Hub router 12 .
[0034] The hub router 12 triggers NHRP Resume Resolution Request towards other remote spoke routers as well, so as to request them to start sending the Resolution Request for the (previously infected spoke router's) Next-hop or prefixes to the Hub router 12 .
[0035] The NHRP Resume Resolution Request message is sent in order to convey that the previously imposed restriction of “No Resolution Request until further Notice” has been removed. This message basically requests the receiver of the Resume Resolution Request, to start sending the NHRP Resolution Requests to the NHRP Server for the relevant destinations.
[0036] After receiving the NHRP Resume Resolution Request message, the spoke router 14 will send a NHRP Resume Resolution Reply message to the hub router (NHS) 12 . The Hub router 12 will start resolving the relevant next-hops or prefixes. The NHRP Resume Resolution Reply message is sent in order to ensure the sender of the Resume Resolution Request, that sender of the Reply has lifted the restriction imposed earlier and is going to start sending the “NHRP Resolution requests” for the relevant destinations.
[0037] In another embodiment NHRP throttling can be employed as a safety measure, This can be accomplished by defining a limit on the number of “NHRP resolution requests” and “NHRP Resolution Replies” at both hub router and spoke routers. This limit could be applied on a per NHC basis. The NHRP throttling rate monitoring, combined with other events, could provide a means to detect a DoS attack.
[0038] While a spoke router site is infected and the prevention of the infection propagation is being pursued, the IPSec SAs between the spoke router of the infected spoke router site and other spoke routers are immediately torn down by the spoke router of the infected spoke router site, and the NHRP cache information for the infected spoke router site doesn't exist anymore. The remote spoke routers will not try to establish sessions. Until then, the traffic in reverse direction is forwarded to the hub router, which could optionally redirect this traffic to the Scrubber as well or directly forward the traffic to the spoke router of the infected spoke router site. This enables the hub router to gain full control on the traffic sent by/to the infected spoke router sites.
[0039] Once all the NHRP next-hop entries get invalidated, the spoke router of the infected spoke router site could potentially continue to send NHRP resolution requests to the hub router for each of the remote spoke router (DMVPN phase 2) or remote prefixes (DMVPN phase 3). Hence, the possibility of hub router getting unstable increases dramatically as there could be thousands of requests pouring in at the hub router. The extension is interpreted by spoke router/NHC as the order to stop sending Resolution Requests until further notice.
[0040] A flow chart of the presently disclosed method is depicted in FIGS. 2A and 2B . The rectangular elements are herein denoted “processing blocks” and represent computer software instructions or groups of instructions. Alternatively, the processing blocks represent steps performed by functionally equivalent circuits such as a digital signal processor circuit or an application specific integrated circuit (ASIC). The flow diagrams do not depict the syntax of any particular programming language. Rather, the flow diagrams illustrate the functional information one of ordinary skill in the art requires to fabricate circuits or to generate computer software to perform the processing required in accordance with the present invention. It should be noted that many routine program elements, such as initialization of loops and variables and the use of temporary variables are not shown. It will be appreciated by those of ordinary skill in the art that unless otherwise indicated herein, the particular sequence of steps described is illustrative only and can be varied without departing from the spirit of the invention. Thus, unless otherwise stated the steps described below are unordered meaning that, when possible, the steps can be performed in any convenient or desirable order.
[0041] Referring now to FIGS. 2A and 2B , a method 100 for preventing infection propagation in a Dynamic Multipoint Virtual Private Network is shown. The method begins with processing block 102 which discloses receiving an indication at a hub router that a spoke router site having a spoke router in communication with the hub router has an infection. The infection may be caused by a Worm/DoS attack and has been detected through an existing/known mechanism (e.g., by a security monitoring application or other type of mechanism) in a specific DMVPN spoke router site.
[0042] Processing block 104 states receiving an indication at a hub router that a spoke router site having a spoke router in communication with the hub router propagating an infection further comprises the hub router sending an Access Control List (ACL) to the spoke router. Processing block 106 recites the spoke router installing the ACL such that the ACL causes traffic from the spoke router to other spoke routers to be dropped at the spoke router. The spoke router will simply install the ACL on either the outbound tunnel interface or the physical interface.
[0043] Processing continues with processing block 108 which discloses the ACL causing traffic from the spoke router to the hub router to be dropped by the spoke router. Optionally, the ACL could be such that even the spoke router-to-Hub router traffic could be dropped, if needed.
[0044] Processing block 110 states wherein the receiving an indication at a hub router that a spoke router site having a spoke router in communication with the hub router has become infected comprises exceeding a limit for one of the group consisting of a number of resolution requests sent from the spoke router to the hub router and a number of resolution replies sent from the hub router to the spoke router. This is known as NHRP throttling and can be employed as a safety measure. This limit could be applied on a per NHC basis. The NHRP throttling rate monitoring, combined with other events, could provide a means to detect a DoS attack.
[0045] Processing block 112 recites sending a purge message to the spoke router, the purge message directing the spoke router to purge all requests. Processing block 114 discloses receiving the purge message at the spoke router.
[0046] Processing block 116 states purging, by the spoke router, cached entries in a forwarding database and refraining from resolving any next-hop requests, to invalidate/flush all the dynamically learned/cached entries within the NHRP database and do not attempt to send any NHRP Resolution Request for them.
[0047] Processing block 118 recites sending, by the spoke router, a purge reply message to the hub router acknowledging the purging of the spoke router database. Since the NHRP database entries are already flushed/invalidated, the IPSec SAs associated with these entries will be torn down and will not be used for the direct spoke router-to-spoke router communication. Thus, spoke router-to-spoke router tunnels are torn down.
[0048] Processing block 120 discloses invalidating, by the hub router, next-hop information for the spoke router at other spoke routers in communication with the hub router. This can be done by letting the hub router also send NHRP Purge Requests to all the spoke routers. The newly defined NHRP Extension “No resolution request until further notice” is also appended within the NHRP Purge Request.
[0049] Processing block 122 states the hub router refusing to receive traffic from the spoke router. This is done until the spoke router site becomes uninfected.
[0050] Processing block 124 recites the hub router receiving traffic from the spoke router and forwarding the traffic to a scrubber. The scrubber separates the bad traffic from the good traffic. Processing block 126 discloses the hub router receiving cleaned traffic from the scrubber, and forwarding the cleaned traffic to appropriate spoke routers.
[0051] Processing block 128 recites receiving an indication at the hub router that the spoke router site having a spoke router in communication with the hub router is no longer infected, and sending a resume message to the spoke router.
[0052] Processing block 130 discloses receiving the resume message at the spoke router, sending a reply to the resume message to the hub router, and sending relevant resolution requests to the hub router.
[0053] FIG. 3 illustrates example architectures of a computer system 240 that is configured as a network device. The computer system 240 may be any type of computerized system such as a personal computer, workstation, portable computing device, mainframe, spoke router, hub router, host, server or the like. In this example, the system includes an interconnection mechanism 211 that couples a memory system 212 , a processor 213 , and a communications interface 214 . The communications interface 214 allows the computer system 240 to communicate with external devices or systems.
[0054] The memory system 212 may be any type of computer readable medium that is encoded with an application 255 -A that represents software code such as data and/or logic instructions (e.g., stored in the memory or on another computer readable medium such as a disk) that embody the processing functionality of embodiments of the invention for the agent 255 as explained above. The processor 213 can access the memory system 212 via the interconnection mechanism 211 in order to launch, run, execute, interpret or otherwise perform the logic instructions of the applications 255 -A for the host in order to produce a corresponding agent process 255 -B. In other words, the agent process 255 -B represents one or more portions of the agent application 255 -A performing within or upon the processor 213 in the computer system. It is to be understood that the agent 255 operate as explained in former examples are represented in FIG. 5 by the agent application 255 -A and/or the process 255 -B.
[0055] It is to be understood that embodiments of the invention include the applications (i.e., the un-executed or non-performing logic instructions and/or data) encoded within a computer readable medium such as a floppy disk, hard disk or in an optical medium, or in a memory type system such as in firmware, read only memory (ROM), or, as in this example, as executable code within the memory system 212 (e.g., within random access memory or RAM). It is also to be understood that other embodiments of the invention can provide the applications operating within the processor 213 as the processes. While not shown in this example, those skilled in the art will understand that the computer system may include other processes and/or software and hardware components, such as an operating system, which have been left out of this illustration for ease of description of the invention.
[0056] The presently described method, software and apparatus for preventing infection propagation in a DMVPN provide an efficient mechanism to prevent the DMVPN melt-down, to isolate a worm-infected spoke router site from the rest of the DMVPN and to restrict the spread of the worm within the DMVPN network.
[0057] Having described preferred embodiments of the invention it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts may be used. Additionally, the software included as part of the invention may be embodied in a computer program product that includes a computer useable medium. For example, such a computer usable medium can include a readable memory device, such as a hard drive device, a CD-ROM, a DVD-ROM, or a computer diskette, having computer readable program code segments stored thereon. The computer readable medium can also include a communications link, either optical, wired, or wireless, having program code segments carried thereon as digital or analog signals. Accordingly, it is submitted that that the invention should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the appended claims.
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A method, apparatus and computer program product for preventing infection propagation in a DMVPN is presented. An infected spoke router site is isolated from the DMVPN network such that the spoke router may (bi-directionally) completely or partially limit communicating with any network devices (including the hub router, any other spoke routers etc.) within the DMVPN which prevents the DMVPN melt-down, isolates a worm-infected spoke router site from the rest of the DMVPN and restricts the spread of the worm within the DMVPN network.
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FIELD OF THE INVENTION
[0001] The present invention relates to pyrrolidine sulfonamides, pharmaceutical compositions containing them and their use as urotensin II antagonists
BACKGROUND OF THE INVENTION
[0002] The integrated control of cardiovascular homeostasis is achieved through a combination of both direct neuronal control and systemic neurohormonal activation. Although the resultant release of both contractile and relaxant factors is normally under stringent regulation, an aberration in this status quo can result in cardiohemodynamic dysfunction with pathological consequences.
[0003] The principal mammalian vasoactive factors that comprise this neurohumoral axis, namely angiotensin-II, endothelin-1, norepinephrine, all function via an interaction with specific G-protein coupled receptors (GPCR). Urotensin-II, represents a novel member of this neurohumoral axis.
[0004] In the fish, this peptide has significant hemodynamic and endocrine actions in diverse end-organ systems and tissues:
[0005] smooth muscle contraction
[0006] both vascular and non-vascular in origin including smooth muscle preparations from the gastrointestinal tract and genitourinary tract. Both pressor and depressor activity has been described upon systemic administration of exogenous peptide
[0007] osmoregulation:
[0008] effects which include the modulation of transepithelial ion (Na + , Cl) transport. Although a diuretic effect has been described, such an effect is postulated to be secondary to direct renovascular effects (elevated GFR)
[0009] metabolism:
[0010] urotensin-II influences prolactin secretion and exhibits a lipolytic effect in fish (activating triacylglycerol lipase resulting in the mobilization of non-esterified free fatty acids)
[0011] (Pearson, et. al. Proc. Natl. Acad. Sci . (U.S.A.) 1980, 77, 5021; Conlon, et. al. J. Exp. Zool. 1996, 275, 226.)
[0012] In studies with human Urotensin-II it was found that it:
[0013] was an extremely potent and efficacious vasoconstrictor
[0014] exhibited sustained contractile activity that was extremely resistant to wash out
[0015] had detrimental effects on cardiac performance (myocardial contractility)
[0016] Human Urotensin-II was assessed for contractile activity in the rat-isolated aorta and was shown to be the most potent contractile agonist identified to date. Based on the in vitro pharmacology and in: vivo hemodynamic profile of human Urotensin-II it plays a pathological role in cardiovascular diseases characterized by excessive or abnormal vasoconstriction and myocardial dysfunction. (Ames et. al. Nature 1999, 401, 282; Douglas & Ohlstein (2001). Trends Cardiovasc. Med., 10: in press). Compounds that antagonize the Urotensin-II receptor may be useful in the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, fibrosis (e.g. pulmonary fibrosis), restenosis, atherosclerosis, dyslipidemia, asthma, (Hay D W P, Luttmann M A, Douglas S A: 2000, Br J Pharmacol: 131; 10-12) neurogenic inflammation and metabolic vasculopathies all of which are characterized by abnormal vasoconstriction and/or myocardial dysfunction. Since U-II and GPR14 are both expressed within the mammalian CNS (Ames et. al. Nature 1999, 401, 282), they also may be useful in the treatment of addiction, schizophrenia, cognitive disorders/Alzheimers disease, (Gartlon J. Psychopharmacology (Berl) 2001 June; 155(4):426-33), impulsivity, anxiety, stress, depression, pain, migraine, and neuromuscular function. Functional U-II receptors are expressed in rhabdomyosarcomas cell lines and therefore may have oncological indications. Urotensin may also be implicated in various metabolic diseases such as diabetes (Ames et. al. Nature 1999, 401, 282, Nothacker et al., Nature Cell Biology 1: 383-385, 1999) and in various gastrointestinal disorders, bone, cartilage, and joint disorders (e.g. arthritis and osteoporosis); and genito-urinary disorders. Therefore, these compounds may be useful for the prevention (treatment) of gastric reflux, gastric motility and ulcers, arthritis, osteoporosis and urinary incontinence.
SUMMARY OF THE INVENTION
[0017] In one aspect this invention provides for pyrrolidine sulfonamides and pharmaceutical compositions containing them.
[0018] In a second aspect, this invention provides for the use of pyrrolidine sulfonamides as antagonists of urotensin II, and as inhibitors of urotensin II.
[0019] In another aspect, this invention provides for the use of pyrrolidine sulfonamides for treating conditions associated with urotensin II imbalance.
[0020] In yet another aspect, this invention provides for the use of pyrrolidine sulfonamides for the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, restenosis, asthma, neurogenic inflammation, migraine, metabolic vasculopathies, bone/cartilage/joint diseases, arthritis and other inflammatory diseases, fibrosis (e.g. pulmonary fibrosis), sepsis, atherosclerosis, dyslipidemia, addiction, schizophrenia, cognitive disorders/Alzheimers disease, impulsivity, anxiety, stress, depression, pain, neuromuscular function, diabetes, gastric reflux, gastric motility disorders, ulcers and genitourinary diseases.
[0021] The urotensin antagonist may be administered alone or in conjunction with one or more other therapeutic agents, said agents being selected from the group consisting of endothelin receptor antagonists, angiotensin converting enzyme (ACE) inhibitors, A-II receptor antagonists, vasopeptidase inhibitors, diuretics, digoxin, and dual non-selective β-adrenoceptor and α 1 -adrenoceptor antagonists.
[0022] Other aspects and advantages of the present invention are described further in the following detailed description of the preferred embodiments thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention provides for compounds of Formula (I):
[0024] wherein:
[0025] R 2 is benzimidazolyl, quinolinyl, benzofuranyl, napthyl, indolyl, or benzothiophenyl, phenyl, furanyl, thienyl, or pyridyl substituted or unsubstituted by one, two or three halogen, C 1-3 alkyl, C 1-3 alkoxy, or methylenedioxy groups;
[0026] R 1 is C 1-6 alkyl, benzyl, or (CH 2 ) n —C(O)NH 2 ; wherein the benzyl may be unsubstituted or substituted by one or two C 1-6 alkyl, halogen, C 1-6 alkoxy, or methylenedioxy groups;
[0027] X 1 and X 2 are independently hydrogen, halogen, C 1-3 alkyl, C 1-3 alkoxy, nitro, CF 3 , or CN;
[0028] n is 1, 2, or 3;
[0029] m is 1, 2 or 3;
[0030] or a pharmaceutically acceptable salt thereof.
[0031] When used herein, the term “alkyl” includes all straight chain and branched isomers. Representative examples thereof include methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, t-butyl, n-pentyl and n-hexyl.
[0032] When used herein, the terms ‘halogen’ and ‘halo’ include fluorine, chlorine, bromine and iodine and fluoro, chloro, bromo and iodo, respectively.
[0033] The compounds of the present invention may contain one or more asymmetric carbon atoms and may exist in racemic and optically active form. All of these compounds and their diastereoisomers are contemplated to be within the scope of the present invention.
[0034] Preferrably:
[0035] m is 1 or 2;
[0036] R 1 is isobutyl;
[0037] R 2 is benzothiopheneyl;
[0038] X 1 is hydrogen, 3-Bromo, or 3-Chloro; and
[0039] X 2 is hydrogen or 5-Chloro.
[0040] Preferred Compounds are:
[0041] Benzo[b]thiophene-2-carboxylic acid [(S)-1-(2-{4-[3-chloro-4-(piperidin-4-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-3-methyl-butyl]-amide
[0042] Benzo[b]thiophene-2-carboxylic acid [(S)-1-(2-{4-[3-bromo-4-(piperidin-4-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-3-methyl-butyl]-amide
[0043] Benzo[b]thiophene-2-carboxylic acid [(S)-1-(2-{4-[3-chloro-4-((S)-pyrrolidin-3-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-3-methyl-butyl]-amide
[0044] Benzo[b]thiophene-2-carboxylic acid [(S)-1-(2-{4-[3-bromo-4-((S)-pyrrolidin-3-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-3-methyl-butyl]-amide
[0045] Benzo[b]thiophene-2-carboxylic acid [(S)-3-methyl-1-(2-{4-[4-(piperidinyloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-butyl]-amide
[0046] Benzo[b]thiophene-2-carboxylic acid [(S)-1-(2-{4-[3,5-dichloro-4-(piperidin-4-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-3-methyl-butyl]-amide
[0047] Compounds of Formula (I) may be prepared as set forth in scheme 1.
[0048] Conditions: a) tert-butylchlorodiphenyl silane, triethylamine, CH 2 Cl 2 , 50° C.; b) 2-nitrobenzenesulfonyl chloride, 0° C.-rt; c) 4 M HCl in 1,4-dioxane, rt; d) 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin), Na(OAc) 3 BH, diisopropylethylamine, 1% acetic acid in 1-methyl-2-pyrrolidinone, rt; e) Fmoc-HNCH(R 1 )COOH, 1,3-diisopropylcarbodiimide, 1-hydroxy-7-azabenzotriazole, 1-methyl-2-pyrrolidinone, rt; f) 20% piperidine in 1-methyl-2-pyrrolidinone, rt; g) R 2 COOH, 1,3-diisopropylcarbodiimide, 1-hydroxy-7-azabenzotriazole, 1-methyl-2-pyrrolidinone, rt; h) K 2 CO 3 , PhSH, 1-methyl-2-pyrrolidinone, rt; i) (X 1 )(X 2 )-4-hydroxy-benzenesulfonyl chloride, 1,2-dichloroethane, 1-methyl-2-pyrrolidinone, rt; j) potassium trimethylsilanolate, tetrahydrofuran, rt; k) R 2 OH, diisopropyl azodicarboxylate, PPh 3 , tetrahydrofuran, −78° C.-rt; 1) 50% trifluoroacetic acid in 1,2-dichloroethane, rt.
[0049] As shown in scheme 1, resin-bound amine 3 was prepared by reductive amination of 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin) piperazinyl-ethylamine HCl salt 2 which was prepared from 1-(2-aminoethyl)piperazine (1). Reactions of resin-bound amine 3 with various amino acids, followed by removal of the protecting group, resulted in the corresponding resin-bound amines 4. Amines 4 were then reacted with various acids to afford the corresponding resin-bound amides 5. Resin-bound amides 5 were subsequently treated with potassium carbonate and thiophenol to give secondary amines 6. Sulfonylation of resin-bound amines 6 with various hydroxy-benzenesulfonyl chlorides, followed by treatment with potassium trimethylsilanolate, produced resin-bound phenols 7. Phenols 7 were then reacted with various alcohols in the presence of triphenylphosphine and diisopropyl azodicarboxylate to give the corresponding resin-bound phenol ethers which were treated with 50% trifluoroacetic acid in 1,2-dichloroethane to afford targeted compounds 8.
[0050] With appropriate manipulation, including the use of alternative nitrogen protecting group(s), the synthesis of the remaining compounds of Formula (I) was accomplished by methods analogous to those above and to those described in the Experimental section.
[0051] In order to use a compound of the Formula (I) or a pharmaceutically acceptable salt thereof for the treatment of humans and other mammals it is normally formulated in accordance with standard pharmaceutical practice as a pharmaceutical composition.
[0052] Compounds of Formula (1) and their pharmaceutically acceptable salts may be administered in a standard manner for the treatment of the indicated diseases, for example orally, parenterally, sub-lingually, transdermally, rectally, via inhalation or via buccal administration.
[0053] Compounds of Formula (I) and their pharmaceutically acceptable salts which are active when given orally can be formulated as syrups, tablets, capsules and lozenges. A syrup formulation will generally consist of a suspension or solution of the compound or salt in a liquid carrier for example, ethanol, peanut oil, olive oil, glycerine or water with a flavoring or coloring agent. Where the composition is in the form of a tablet, any pharmaceutical carrier routinely used for preparing solid formulations may be used. Examples of such carriers include magnesium stearate, terra alba, talc, gelatin, agar, pectin, acacia, stearic acid, starch, lactose and sucrose. Where the composition is in the form of a capsule, any routine encapsulation is suitable, for example using the aforementioned carriers in a hard gelatin capsule shell. Where the composition is in the form of a soft gelatin shell capsule any pharmaceutical carrier routinely used for preparing dispersions or suspensions may be considered, for example aqueous gums, celluloses, silicates or oils and are incorporated in a soft gelatin capsule shell.
[0054] Typical parenteral compositions consist of a solution or suspension of the compound or salt in a sterile aqueous or non-aqueous carrier optionally containing a parenterally acceptable oil, for example polyethylene glycol, polyvinylpyrrolidone, lecithin, arachis oil, or sesame oil.
[0055] Typical compositions for inhalation are in the form of a solution, suspension or emulsion that may be administered as a dry powder or in the form of an aerosol using a conventional propellant such as dichlorodifluoromethane or trichlorofluoromethane.
[0056] A typical suppository formulation comprises a compound of Formula (1) or a pharmaceutically acceptable salt thereof which is active when administered in this way, with a binding and/or lubricating agent, for example polymeric glycols, gelatins, cocoa-butter or other low melting vegetable waxes or fats or their synthetic analogues.
[0057] Typical transdermal formulations comprise a conventional aqueous or non-aqueous vehicle, for example a cream, ointment, lotion or paste or are in the form of a medicated plaster, patch or membrane.
[0058] Preferably the composition is in unit dosage form, for example a tablet, capsule or metered aerosol dose, so that the patient may administer to themselves a single dose.
[0059] Each dosage unit for oral administration contains suitably from 0.1 mg to 500 mg/Kg, and preferably from 1 mg to 100 mg/Kg, and each dosage unit for parenteral administration contains suitably from 0.1 mg to 100 mg, of a compound of Formula (I) or a pharmaceutically acceptable salt thereof calculated as the free acid. Each dosage unit for intranasal administration contains suitably 1-400 mg and preferably 10 to 200 mg per person. A topical formulation contains suitably 0.01 to 1.0% of a compound of Formula (I).
[0060] The daily dosage regimen for oral administration is suitably about 0.01 mg/Kg to 40 mg/Kg, of a compound of Formula (1) or a pharmaceutically acceptable salt thereof calculated as the free acid. The daily dosage regimen for parenteral administration is suitably about 0.001 mg/Kg to 40 mg/Kg, of a compound of the Formula (1) or a pharmaceutically acceptable salt thereof calculated as the free acid. The daily dosage regimen for intranasal administration and oral inhalation is suitably about 10 to about 500 mg/person. The active ingredient may be administered from 1 to 6 times a day, sufficient to exhibit the desired activity.
[0061] These sulphonamide analogs may be used for the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, restenosis, asthma, neurogenic inflammation and metabolic vasculopathies, addiction, schizophrenia, impulsivity, anxiety, stress, depression, neuromuscular function, and diabetes.
[0062] The urotensin antagonist may be administered alone or in conjunction with one or more other therapeutic agents, said agents being selected from the group consisting of endothelin receptor antagonists, angiotensin converting enzyme (ACE) inhibitors, vasopeptidase inhibitors, diuretics, digoxin, and dual non-selective β-adrenoceptor and α 1 -adrenoceptor antagonists.
[0063] No unacceptable toxicological effects are expected when compounds of the invention are administered in accordance with the present invention.
[0064] The biological activity of the compounds of Formula (I) are demonstrated by the following tests:
[0065] Radioligand Binding:
[0066] HEK-293 cell membranes containing stable cloned human and rat GPR-14 (20 ug/assay) were incubated with 200 pM [125I] h-U-II (200 Ci/mmol −1 in the presence of increasing concentrations of test compounds in DMSO (0.1 nM to 10 uM), in a final incubation volume of 200 ul (20 mM Tris-HCl, 5 mM MgCl2). Incubation was done for 30 minutes at room temperature followed by filtration GF/B filters with Brandel cell harvester. 125 I labeled U-II binding was quantitated by gamma counting. Nonspecific binding was defined by 125 I U-II binding in the presence of 100 nM of unlabeled human U-II. Analysis of the data was performed by nonlinear least square fitting.
[0067] Ca 2+ -Mobilization:
[0068] A microtitre plate based Ca 2+ -mobilization FLIPR assay (Molecular Devices, Sunnyvale, Calif.) was used for the functional identification of the ligand activating HEK-293 cells expressing (stable) recombinant GPR-14. The day following transfection, cells were plated in a poly-D-lysine coated 96 well black/clear plates. After 18-24 hours the media was aspirated and Fluo 3AM-loaded cells were exposed to various concentrations (10 nM to 30 uM) of test compounds followed by h-U-II. After initiation of the assay, fluorescence was read every second for one minute and then every 3 seconds for the following one minute. The inhibitory concentration at 50% (IC50) was calculated for various test compounds.
[0069] Inositol Phosphates Assays:
[0070] HEK-293-GPR14 cells in T150 flask were prelabeled overnight with 1 uCi myo-[ 3 H] inositol per ml of inositol free Dulbecco's modified Eagel's medium. After labeling, the cells were washed twice with Dulbecco's phosphate-buffered saline (DPBS) and then incubated in DPBS containing 10 mM LiCl for 10 min at 37° C. The experiment was initiated by the addition of increasing concentrations of h-U-II (1 pM to 1 μM) in the absence and presence of three different concentrations (0.3, 1 and 10 uM) of test compounds and the incubation continued for an additional 5 min at 37° C. after which the reaction was terminated by the addition of 10% (final concentration) trichloroacetic acid and centrifugation. The supernatants were neutralized with 100 ul of 1M Trizma base and the inositol phosphates were separated on AG 1-X8 columns (0.8 ml packed, 100-200 mesh) in formate phase. Inositol monophosphate was eluted with 8 ml of 200 mM ammonium formate. Combined inositol di and tris phosphate was eluted with 4 ml of 1M ammonium formate/0.1 M formic acid. Eluted fractions were counted in beta scintillation counter. Based on shift from the control curve K B was calculated.
[0071] Activity for the compounds of this invention range from (radioligand binding assay): Ki=5 nM−10000 nM (example 5 Ki=1400 nM)
[0072] The following Examples are illustrative but not limiting embodiments of the present invention.
Example 1
[0073] Preparation of Benzo[b]thiophene-2-carboxylic Acid [(S)-3-methyl-1-(2-{4-[4-(piperidin-4-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-butyl]-amide
[0074] a) 2-[4-(2-Nitro-benzenesulfonyl)-piperazin-1-yl]-ethylamine HCl Salt
[0075] To a solution of 100 mL (760.8 mmol) of 1-(2-aminoethyl)piperazine in 636 mL (4.56 mol) of triethylamine and 800 mL of anhydrous CH 2 Cl 2 at rt under argon was added 198 mL (760.8 mmol) of tert-butylchlorodiphenyl silane. The mixture was refluxed at 50° C. for 2.5 h. The mixture was then cooled to 0° C. 168.6 g (760.8 mmol) of 2nitrobenzenesulfonyl chloride was added to the mixture in 3 portions. The resulting mixture was stirred at 0° C. for 1 h and warmed to rt and stirred at rt for 16 h. The mixture was diluted with 1.5 L of CH 2 Cl 2 and poured into 1 L of 1 M NaHCO 3 aqueous solution. After stirring for 15 min, the organic layer was separated and washed with 1 L of 1 M NaHCO 3 aqueous solution. The resulting organic layer was dried over K 2 CO 3 and concentrated ill vacuo. The residue was dissolved into 400 mL of 1,4-dioxane. The solution was concentrated in vacuo to remove the remaining triethylamine.
[0076] The above residue was dissolved in 1 L of anhydrous 1,4-dioxane and was diluted with 2 L of anhydrous ether. The resulting mixture was treated with 800 mL of 4 M HCl solution in 1,4-dioxane under argon. The mixture was vigorously stirred at rt under argon for 1 h. The resulting suspension was filtered. The precipitation was washed 5 times with 500 mL portions of anhydrous ether. The resulting solid was dried in vacuum oven for 24 h to yield 2-[4-(2-nitro-benzenesulfonyl)-piperazin-1-yl]-ethylamine HCl salt as a white solid (340 g, 80% pure): MS (ESI) 315 [M+H]+(which was contaminated with 20% of the dinosyl-protected amine HCl salt: MS (ESI) 500 [M+H] + . It is not necessary to purify the crude product, however, the pure amine HCl salt example 1-a could be obtained via recrystallization of the crude product in MeOH).
[0077] b) 4-Hydroxybenzenesulfonyl Chloride
[0078] To chlorosulfonic acid (248 mL, 3.37 mol) cooled to −3° C. was added dropwise a solution of phenol (70 g, 0.744 mol) in 250 mL of anhydrous methylene chloride over a period of 1 hour under argon gas. The mixture was warmed to rt over 1 h and was stirred at rt for 1.5 h. The mixture was poured over ice, stirred for 30 min, and was extracted with methylene chloride (4×2 L). The resulting organic layer was dried over MgSO 4 and concentrated iii vacuo to yield 4-hydroxybenzenesulfonyl chloride as a sticky brown solid (41.49 g, 29%): 1 H NMR (400 MHz, d 6 -DMSO) δ 7.29-7.38 (d, 2H), 6.58-6.69 (d, 2H).
[0079] c) Benzo[b]thiophene-2-carboxylic acid [(S)-3-methyl-1-(2-{4-[4-(piperidin-4-yloxy)-benzenesulfonyl]-piperazin-1-yl}-ethylcarbamoyl)-butyl]-amide
[0080] To a mixture of 20.20 g (29.08 mmol, 1.44 mmol) of 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin) in 439.4 mL of 1% acetic acid in anhydrous 1-methyl-2-pyrrolidinone was added 27.42 g (70.8 mmol) of 2-[4-(2-nitro-benzenesulfonyl)-piperazin-1-yl]-ethylamine HCl salt and 25.33 mL (145.4 mmol) of diisopropylethyl amine, followed by addition of 30.8 g (145.4 mmol) of sodium triacetoxyborohydride. After the resulting mixture was shaken at rt for 65 h under argon gas, the resin was washed with CH 2 Cl 2 /methanol (1:1, 3×400 mL), DMF (3×400 mL), CH 2 Cl 2 (1×400 mL) and methanol (2×400 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. Elemental analysis N: 4.27, S: 5.25.
[0081] To a mixture of 10 g (7.914 mmol, 0.7914 mmol/g) of the above resin in 165 mL of anhydrous 1-methyl-2-pyrrolidinone was added 13.985 g (39.57 mmol) of Fmoc-Leu-OH and 1.077 g (7.914 mmol) of 1-hydroxy-7-azabenzotriazole, followed by addition of 7.490 mL (47.48 mmol) of 1,3-diisopropylcarbodiimide. After the resulting mixture was shaken at rt for 44 h, the resin was washed with 1-methyl-2-pyrrolidinone (3×150 mL), dichloroethane/methanol (1:1, 3×150 mL) and methanol (3×150 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 621 [M+H] + .
[0082] The above resin (7.914 mmol) was treated with 175 mL of 20% piperidine in anhydrous 1-methyl-2-pyrrolidinone solution. After the mixture was shaken at rt for 15 min, the solution was drained and another 175 mL of 20% piperidine in anhydrous 1-methyl-2-pyrrolidinone solution was added. The mixture was shaken at rt for another 15 min. The solution was drained and the resin was washed with 1-methyl-2-pyrrolidinone (3×175 mL), CH 2 Cl 2 /MeOH (1:1, 3×175 mL) and CH 2 Cl 2 (3×175 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 399 [M+H] + .
[0083] To a mixture of 200 mg (0.1453 mmol, 0.7264 mmol/g) of the above dry resin in 5 mL of anhydrous 1-methyl-2-pyrrolidinone was added 129.5 mg (0.7265 mmol) of benzo[b]thiophene-2-carboxylic acid and 19.8 mg (0.1453 mmol) of 1-hydroxy-7-azabenzotriazole, followed by addition of 0.137 mL (0.8718 mmol) of 1,3-diisopropylcarbodiimide. After the resulting mixture was shaken at rt for 48 h, the resin was washed with 1-methyl-2-pyrrolidinone (3×10 mL), CH 2 Cl 2 /MeOH (1:1, 3×10 mL) and CH 2 Cl 2 (3×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 559 [M+H] + .
[0084] To a mixture of 0.1453 mmol of the above dry resin in 6 mL of 1-methyl-2-pyrrolidinone was added 200.8 mg (1.453 mmol) of K 2 CO 3 and 0.0746 mL (0.7265 mmol) of PhSH. After the resulting mixture was shaken at rt for 20 h, the resin was washed with methanol (1×10 mL), H 2 O (3×10 mL), methanol (1×10 mL), 1-methyl-2-pyrrolidinone (1×10 mL), CH 2 Cl 2 /methanol (1:1, 3×10 mL) and methanol (3×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 747 [2M+H] + , 374 [M+H] + .
[0085] To a mixture of 0.1453 mmol of the above dry resin in anhydrous dichloroethane/1-methyl-2-pyrrolidinone solution (1:1, 7.5 mL) was added 0.2264 mL (2.799 mmol) of pyridine followed by the slow addition of 0.5393 g (2.799 mmol) of 4-hydroxybenzenesulfonyl chloride. After the resulting mixture was shaken at rt for 96 h, the resin was washed with 1-methyl-2-pyrrolidinone (3×10 mL), dichloroethane/methanol (1:1, 3×10 mL), dichloroethane (3×10 mL), methanol (1×10 mL), and dichloroethane (2×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. To a mixture of the dry resin in anhydrous tetrahydrofuran (9.38 mL) was added 0.4713 g (3.674 mmol) of potassium trimethyl silanolate. After the reaction mixture was shaken for 23 h, the resin was washed with tetrahydrofuran (3×10 mL), 1-methyl-2-pyrrolidinone (2×10 mL), tetrahydrofuran (3×10 mL), dichloroethane/methanol (5×10 mL), and dichloroethane (3×10 mL). An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 530 [M+H] + .
[0086] To a mixture of 200 mg of the above dry resin in 8.75 mL of anhydrous tetrahydrofuran was added 443 mg (2.199 mmol) of 4-Hydroxypiperidine-1-carboxylic acid tert-butyl ester and 577 mg (2.199 mmol) of triphenylphosphine. After the mixture was cooled to −70° C., 433 mL (2.199 mmol) of diisopropyl azodicarboxylate was added to the cold mixture. The resulting mixture was kept at −70° C. for 30 min while shaking. The mixture was then allowed to warm to 0° C. over 1 h and shaken at rt for 19 h. The resin was washed with tetrahydrofuran (3×10 mL), CH 2 Cl 2 /methanol (1:1, 10×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. The dry resin was treated with 4 mL of 50% trifluoroacetic acid in dichloroethane at rt for 2 h. After the cleavage solution was collected, the resin was treated with another 4 mL of 50% trifluoroacetic acid in dichloroethane at rt for 10 min. The combined cleavage solutions were concentrated in vacuo. The residue was purified using a Gilson semi-preparative HPLC system with a YMC ODS-A (C-18) column 50 mm by 20 mm ID, eluting with 10% B to 90% B in 3.2 min, hold for 1 min where A=H 2 O (0.1% trifluoroacetic acid) and B=CH 3 CN (0.1% trifluoroacetic acid) pumped at 25 mL/min, to produce benzo[b]thiophene-2-carboxylic acid ((S)-3-methyl-1-{1-[4-(piperidin-4-yloxy)-benzenesulfonyl]-piperidin-4-ylcarbamoyl}-butyl)-amide as a mono-trifluoroacetic acid salt (white powder, 23.0 mg, 28% over 11 steps): MS (ESI) 642 [M+H] + .
[0087] Compounds Derived From Scheme 1:
MS (ES+) Example R1 R2 R3 X1 X2 m/e 2 isobutyl benzothiopheneyl piperidin-4-yl 3-chloro H 676 (M + H) 3 isobutyl benzothiopheneyl piperidin-4-yl 3-bromo H 720 (M + H) 4 isobutyl benzothiopheneyl piperidin-4-yl 3-chloro 5-chloro 610 (M + H) 5 isobutyl benzothiopheneyl pyrrolidin- H H 628 (M + H) 3(R)-yl 6 isobutyl benzothiopheneyl pyrrolidin- 3-chloro H 662 (M + H) 3(R)-yl 7 isobutyl benzothiopheneyl pyrrolidin- 3-bromo H 707 (M + H) 3(R)-yl 8 isobutyl benzothiopheneyl pyrrolidin- 3-chloro 5-chloro 696 (M + H) 3(R)-yl 9 isobutyl benzothiopheneyl pyrrolidin- 3-chloro H 662 (M + H) 3(S)-yl 10 isobutyl benzothiopheneyl pyrrolidin- 3-bromo H 707 (M + H) 3(S)-yl
Example 11
[0088] Formulations for pharmaceutical use incorporating compounds of the present invention can be prepared in various forms and with numerous excipients. Examples of such formulations are given below.
Tablets/Ingredients Per Tablet 1. Active ingredient 40 mg (Cpd of Form. I) 2. Corn Starch 20 mg 3. Alginic acid 20 mg 4. Sodium Alginate 20 mg 5. Mg stearate 1.3 mg 2.3 mg
[0089] Procedure for Tablets:
[0090] Step 1: Blend ingredients No. 1, No. 2, No. 3 and No. 4 in a suitable mixer/blender.
[0091] Step 2: Add sufficient water portion-wise to the blend from Step 1 with careful mixing after each addition. Such additions of water and mixing until the mass is of a consistency to permit its conversion to wet granules.
[0092] Step 3: The wet mass is converted to granules by passing it through an oscillating granulator using a No. 8 mesh (2.38 mm) screen.
[0093] Step 4: The wet granules are then dried in an oven at 140° F. (60° C.) until dry.
[0094] Step 5: The dry granules are lubricated with ingredient No. 5.
[0095] Step 6: The lubricated granules are compressed on a suitable tablet press.
[0096] Inhalant Formulation
[0097] A compound of Formula I, (1 mg to 100 mg) is aerosolized from a metered dose inhaler to deliver the desired amount of drug per use.
[0098] Parenteral Formulation
[0099] A pharmaceutical composition for parenteral administration is prepared by dissolving an appropriate amount of a compound of formula I in polyethylene glycol with heating. This solution is then diluted with water for injections Ph Eur. (to 100 ml). The solution is then sterilized by filtration through a 0.22 micron membrane filter and sealed in sterile containers.
[0100] The above specification and Examples fully disclose how to make and use the compounds of the present invention. However, the present invention is not limited to the particular embodiments described hereinabove, but includes all modifications thereof within the scope of the following claims. The various references to journals, patents and other publications which are cited herein comprise the state of the art and are incorporated herein by reference as though fully set forth.
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The present invention relates to pyrrolidine sulfonamides, pharmaceutical compositions containing them and their use as urotensin II antagonists.
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FIELD OF THE INVENTION
This invention relates generally to hydrodynamic or self-acting gas bearings, and more particularly to bearing arrangements in which the replenishment gas is drawn through a filter as required by the operating bearings.
BACKGROUND OF THE INVENTION
Low friction, self-acting gas bearings rely on the relative rotation of the bearing members to form the supporting bearing film from the ambient atmosphere. This atmosphere is usually air, but may be other gases if the bearing is sufficiently isolated. The gap or clearance between the surface of the rotating member and that of the stationary member is frequently on the order of one hundred microinches. Gas borne particles larger than this size can be sucked or drawn into the dynamically changing film and damage one or both of the mating bearing surfaces.
In some gas bearings, the gas required for the supporting film is supplied directly to the bearing from a pressurized source and is known as jacking fluid. Gas entering the source can be selected or filtered to prevent the entrance of oversized particles. Self-acting gas bearings, however, are usually started, stopped, and operate in an environment that includes the bearing drive or load or is amidst wear particles that are produced by nearby mechanisms. It then becomes difficult to insure that replenishment gas for the bearing film is clear of occasional oversize particles that can spall or gouge the bearing surface.
Attempts have been made to trap the damaging bits with filters in self-acting gas bearings, but the filters have been placed either at the entrance to the mechanism chamber enclosing the bearing, drive and load, which are themselves particle generators, or have been placed at the exit for the gas from the bearing. Typical of such arrangements are U.S. Pat. Nos. 4,656,545, issued Apr. 7, 1987 to K. Kakuta and 4,547,081, issued Oct. 15, 1985 to K. Tanaka et al. In each of these references, the gas for the supporting bearing film is either filtered as it enters a chamber enclosing a motor and disc drive or after the gas has passed through a drive motor and the gas bearing. The bearing gas is filtered too late to intercept wear or dirt particles and prevent them entering the narrow gas film opening crucial to bearing operation.
OBJECTS AND SUMMARY OF THE INVENTION
It is accordingly a primary object of this invention to provide a hydrodynamic gas bearing for which ambient gas entering the bearing is required to be drawn through filtering means immediately prior to use as a support film in the bearing to insure that the gas is free of damaging particles.
Another important object of this invention is to provide a method of supplying filtered gas for hydrodynamic journal or thrust bearings to which the filtered gas is supplied according to the demand of the bearings.
Yet another important object of this invention is to provide a pumping arrangement for the gas supply of a hydrodynamic or self-acting thrust or journal bearing in which a surplus of filtered gas is drawn adjacent to the bearing to further assure that unfiltered gas is not consumed in the bearing.
The foregoing objects are attained in accordance with the present invention by providing thrust or journal hydrodynamic or self-acting gas bearings with gas pumping means for their necessary support film supply and limiting the supply channels for the gas to only paths that incorporate filtering means. The filtering means is capable of removing airborne particles of sizes sufficient to damage the bearing components. The gas pumping means is of a capacity to draw the required gas or an excess quantity of gas to the entrance to the bearing opening and thus prevent unfiltered ambient gas and particles from entering the bearing gaps.
The present inventive arrangement has the advantage of avoiding bearing shielding or confinement or the requirement that the bearing be supplied with externally pressurized gas. Pumping capability can be easily and inexpensively provided for the hydrodynamic bearings. Since the demand for replacement gas is not great in high quality hydrodynamic bearings, the supply channels and filtering means do not require significant structure and can be kept small. Bearing clearance can be minimized since filtered gas is assured.
Additional objects, features and advantages of the invention will become apparent from the following, more particular description of a preferred embodiment of the invention with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is sectional elevation view of a hydrodynamic gas bearing incorporating a filter arrangement constructed in accordance with the principles of the invention;
FIG. 2 is sectional view taken along the line 2--2 shown in FIG. 1;
FIG. 3 is a sectional view taken along the line 3--3 in FIG. 1; and
FIG. 4 is a modification of the embodiment of the invention shown in FIGS. 1-3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, right circular cylinder 10 is fixed on an input/output shaft 11 and rotates within stationary journal sleeve 12 on a film of gas in the narrow gap or clearance 13. The gas film in this instance may be assumed to be air from the ambient atmosphere, and the film is formed by the relatively rotating adjacent surfaces of the cylinder and sleeve. The air film serves as the supporting lubricant as in a typical gas or air bearing. The sleeve and cylinder are finished to geometric accuracies of ten microinches and are dimensioned to provide a radial gap of approximately 100 microinches.
Shaft 11 has annular shoulders 14 and surfaces 16, 17 to which exemplary driving or driven elements 18, 19 can be secured by nuts 20. For example, element 18 can be the rotor of a drive motor and element 19 may be a magnetic disc hub or fan. Sleeve 12 has secured at either end thereof an end plate 21 that accomodates shoulder 16 or 17 of the rotating shaft with clearance. Each end plate is formed with at least one radially extending channel 22 and counterbore 23 that communicates with the end plate opening at a shoulder 14 of the shaft. In FIG. 1, two oppositely disposed channels 22 have been shown in each end plate 21 and additional ones may be provided. Each counterbore 23 is filled with suitable submicron filter material 24, such as "Microfibre" from Balston, Inc., Lexington, Mass., that will intercept airborne particles equal to or larger than those expected to damage the inner surface of sleeve 12 or outer surface of cylinder 10 rotating adjacent to the sleeve.
Inner face 25 of each end plate 21 lying next to the ends 10a of cylinder 10 is formed with a plurality of spiral or "Whipple" grooves or flutes 26, best seen in FIG. 2. These grooves are commonly used to pump the gas and produce a supporting end thrust film at the cylinder ends that serve as thrust bearings. Gas is also urged into the journal bearing. The grooves extend only part way along the coextensive surfaces of endplates 21 and cylinder 10. Clamped between each shoulder 14 and input or output element 18 or 19 is a washer 27 having on its face 28 adjacent to shoulder 14 a pattern of radial ribs 29, FIG. 3, that serve to evacuate gas from the opening near shoulder 14. The ribs pump the gas outwardly between element 18 or 19 and end plate 21 to insure a surplus flow of gas through channels 22. Ribs 29 can be of various configuration, such as those forming grooves 26 on face 25 of end plate 21 or the washer surface can be plain. Pumping action will still occur since pumping depends on speed, clearance and washer diameter. The clearance between shoulders 14 and the mating openings in end plates 21, and the washer 27 and the end plate is much larger than that of the bearing air gap between sleeve and cylinder or between end plate and cylinder. The bearing clearance may be only a fifth or tenth that of the other clearances.
In operation, cylinder 10 and its shaft 11 are rotated within stationary sleeve 12 by an input source of energy, such as element 18. The relative motion between the ends of cylinder 10 and journal sleeve 12 with its end plate grooves 26 forms a radial support gas film and end thrust gas film on which the cylinder and shaft move. The pumping grooves or flutes 26 urge the gas into the thrust bearing and journal bearing gap, thus drawing any replenishment gas from the shoulder-end of channels 22 after the gas has passed through filters 24. This assures entrapment of potentially damaging particulate prior to its entry into the radial and thrust bearings. Gas is also forced outward between end plates 21 and input or output elements 18 and 19. The larger clearances, however, decrease the effective pumping action so that the gas is drawn in continually and slowly through channels 22, but without producing a significant negative pressure or overcoming the pumping of grooves 26. The outward flow of gas away from the bearing film assures that any necessary gas has been filtered.
In a different embodiment, in FIG. 4, gas supply channels 22, counterbores 23 with filters 24 can be placed near the center of journal sleeve 12 between end plates 21 and grooves 26 can be reversed and arranged to pull gas through the filters into the journal first, then between the thrust surfaces of the ends of cylinder 10 and end plates 21, and out to the atmosphere adjacent shoulders 14. Washers 27 would continue to provide an exhaust function for the gas as it passes from the journal through the thrust bearings. A region of decreased atmospheric pressure is created in the journal bearing in this embodiment.
The self-cleaning gas bearing described above can be modified in several other aspects: for example, the bearing may be oriented with shaft 11 being vertical or at some other acute angle with respect to the horizontal; this would require only a single thrust bearing. Although the bearing has been illustrated with a rotating cylinder 10, sleeve 12 may be rotated instead; self-cleaning is functional with relative rotation of the bearing members. Pumpimg grooves 26 can be formed on the ends 10a of cylinder 10, and along with ribs 29 can be modified as necessary to provide the desired bearing film of gas flow through the supply channels. In addition, the number and location of channels 22 can be varied to meet the particular bearing arrangement.
Even though the illustrative bearing has been disclosed as an air bearing, the entire mechanism can be enclosed in an atmosphere of another gas and function as described. Manufacturing devices may have to operate in gas atmospheres, such as nitrogen, and the filtering arrangement of the invention is equally effective in these environments.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.
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Gas bearing of the hydrodynamic self-acting type in which replenishment gas for the support film is drawn by the operating bearing through filter means as required to assure entrapment of potentially damaging particles before they can enter the gas film in the narrow clearance between the rotating and stationary bearing members. To further increase the flow of filtered gas, the bearing elements may optionally be equipped with supplemental gas pumping apparatus.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present disclosure relates in general to a modular system for pumping drilling mud from subsea to above the sea surface.
[0003] 2. Description of Prior Art
[0004] Subsea drilling systems typically employ a vessel at the sea surface, a riser connecting the vessel with a wellhead housing on the seafloor, and a drill string. A drill bit is attached on a lower end of the drill string, and used for excavating a borehole through the formation below the seafloor. The drill string is suspended subsea from the vessel into the riser, and is protected from seawater while inside of the riser. Past the lower end of the riser, the drill string inserts through the wellhead housing just above where it contacts the formation. Generally, a rotary table or top drive is provided on the vessel for rotating the string and bit. Drilling mud is usually pumped under pressure into the drill string, and is discharged from nozzles in the drill bit. The drilling mud, through its density and pressure, controls pressure in the well and cools the bit. The mud also removes formation cuttings from the well as it is circulated back to the vessel. Traditionally, the mud exiting the well is routed through an annulus between the drill string and riser. However, as well control depends at least in part on the column of fluid in the riser, the effects of corrective action in response to a well kick or other anomaly can be delayed.
[0005] Fluid lift systems have been deployed subsea for pressurizing the drilling mud exiting the wellbore. Piping systems outside of the riser carry the mud pressurized by the subsea lift systems. The lift systems include pumps disposed proximate the wellhead, which reduce the time for well control actions to take effect.
SUMMARY OF THE INVENTION
[0006] Disclosed herein are examples of a system and method of lifting drilling fluid from a subsea wellbore to above the sea surface. In one example, disclosed is a system for lifting the drilling fluid from a subsea wellbore that includes a drilling riser having a return flow of the drilling fluid, a subsea module coupled with the drilling riser and having piping, and that is transportable to the drilling riser on a vessel having a capacity that is less than a capacity of a rig used in conjunction with the drilling riser. Also included is a riser module coupled with the drilling riser and having controls, and that is transportable to the drilling riser on the vessel, and a pump module coupled with the drilling riser. The pump module has a pump that is in fluid communication with the drilling fluid in the drilling riser via the piping in the subsea module and that is in communication with the controls in the riser module. The pump module is transportable to the drilling riser on the vessel. The pump module can be a first pump module, in this example the system further includes a second pump module that is symmetric and interchangeable with the first pump module. Further in this example, each pump module includes three pumps. Each pump may have a housing, a water space in the housing, a mud space in the housing that is in pressure communication with the water space, a bladder mounted in the housing having a side in contact with the water space and an opposing side in contact with the mud space, and that defines a barrier between the water and mud space. Optionally, the pump module, the subsea module, and the riser module each have a weight less than 50 metric tons. In an optional embodiment, the piping in the subsea module includes a portion for bypassing the pump module.
[0007] Also disclosed herein is an example method of lifting drilling fluid from subsea that includes providing a pump module having a series of pumps, providing a riser module having controls for the pump module, providing a subsea module having piping, forming a mud pump kit by coupling together the pump module, riser module, and subsea module, coupling the mud pump kit with a subsea riser, flowing mud from the riser to the pump module via the subsea module, and lifting the mud to above sea surface by pressurizing the mud with the pumps in the pump module. Alternatively, a second pump module can be included that is symmetric with the first pump module, so that the first and second pump modules can be interchangeable. In an example, the pump module, the subsea module, and the riser module are transported individually to a drilling riser on the sea surface with a vessel having a limited capacity. A spare pump module can be optionally provided, where the method further includes replacing the pump module with the spare pump module. The pump module can be controlled with the controls from the riser module. In one alternative, mud flow is bypassed around the pump module and through the subsea module.
[0008] Another example method of lifting drilling fluid from subsea includes providing first and second pump modules that are symmetric to one another. In this example, each of the pump modules has a series of pumps. The method further includes providing a riser module having controls for the pump modules, providing a subsea module having piping; and transporting the first pump module, the second pump module, the riser module, and subsea module on a vessel and to an offshore rig. Here, each of the pump modules, the riser module, and subsea module are individually transported to the rig on the vessel. A mud pump kit is formed by coupling together the pump modules, riser module, and subsea module on the offshore rig, and the mud pump kit is coupled with a subsea riser that is operated in conjunction with the offshore rig. Mud is flowed from the riser to the pump modules via the subsea module, and the mud is lifted to above sea surface by pressurizing the mud in the pump modules. A spare pump module can optionally be provided; where the spare pump module is used to replace one of the first or second pump modules. In one alternative, the controls in the riser module include a processor and hydraulic power units, the method of this example can further include using the processor to selectively open and close valves provided with the pump modules.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a side sectional view of an example of a subsea drilling system in accordance with the present invention.
[0011] FIGS. 2 and 3 are partial side sectional views of an example of a subsea pump for use with the drilling system of FIG. 1 in different pumping modes and in accordance with the present invention.
[0012] FIG. 4 is a side view of an embodiment of an example of a lift pump assembly in accordance with the present invention.
[0013] FIG. 5 is a side view of an alternate embodiment of the drilling system of FIG. 1 and in accordance with the present invention.
[0014] FIG. 6 is a perspective view of a portion of the drilling system of FIG. 6 , and in accordance with the present invention.
[0015] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0016] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0017] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
[0018] Shown in FIG. 1 is a side partial sectional view of an example embodiment of a drilling system 10 for forming a wellbore 12 subsea. The wellbore 12 intersects a formation 14 that lies beneath the sea floor 16 . The wellbore 12 is formed by a rotating bit 18 coupled on an end of a drill string 20 shown extending subsea from a vessel 22 floating on the sea surface 24 . The drill string 20 is isolated from seawater by an annular riser 26 ; whose upper end connects to the vessel 22 and lower end attaches onto a blowout preventer (BOP) 28 . The BOP 28 mounts onto a wellhead housing 30 that is set into the sea floor 16 over the wellbore 12 . A mud return line 32 is shown having an end connected to the riser 26 above BOP 28 , which routes drilling mud exiting the wellbore 12 to a lift pump assembly 34 schematically illustrated subsea. Within the lift pump assembly 34 , drilling mud is pressurized for delivery back to the vessel 22 via mud return line 36 .
[0019] FIG. 2 includes a side sectional view of an example of a pump 38 for use with lift pump assembly 34 ( FIG. 1 ). Pump 38 includes a generally hollow and elliptically shaped pump housing 40 . Other shapes for the housing 40 include circular and rectangular, to name a few. An embodiment of a flexible bladder 42 is shown within the housing 40 ; which partitions the space within the housing 40 to define a mud space 44 on one side of the bladder 42 , and a water space 46 on an opposing side of bladder 42 . As will be described in more detail below, bladder 42 provides a sealing barrier between mud space 44 and water space 46 . In the example of FIG. 2 , bladder 42 has a generally elliptical shape and an upper open space 48 formed through a side wall. Upper open space 48 is shown coaxially registered with an opening 50 formed through a side wall of pump housing 40 . A disk-like cap 52 bolts onto opening 50 , where cap 52 has an axially downward depending lip 53 that coaxially inserts within opening 50 and upper open space 48 . A portion of the bladder 42 adjacent its upper open space 48 is wedged between lip 53 and opening 50 to form a sealing surface between bladder 42 and pump housing 40 .
[0020] A lower open space 54 is formed on a lower end of bladder 42 distal from upper open space 48 , which in the example of FIG. 2 is coaxial with upper open space 48 . An elliptical bumper 56 is shown coaxially set in the lower open space 54 . The bumper 56 includes upper and lower segments 58 , 60 coupled together in a clamshell like arrangement, and that respectively seal against upper and lower radial surfaces on the lower open space 54 . The combination of sealing engagement of cap 52 and bumper 56 with upper and lower open spaces 42 , 54 of bladder 42 , effectively define a flow barrier across the opposing surfaces of bladder 42 . Further shown in the example of FIG. 2 is an axial rod 62 that attaches coaxially to upper segment 56 and extends axially away from lower segment 58 and through opening 50 .
[0021] Still referring to FIG. 2 , a mud line 64 is shown having an inlet end connected to mud return line 32 , and an exit end connected with mud return line 36 . A mud inlet valve 66 in mud line 64 provides selective fluid communication from mud return line 32 to a mud lead line 68 shown branching from mud line 64 . Lead line 68 attaches to an annular connector 70 , which in the illustrated example is bolted onto housing 40 . Connector 70 mounts coaxially over an opening 72 shown formed through a sidewall of housing 40 and allows communication between mud space 44 and mud line 64 through lead line 68 . A mud exit valve 74 is shown in mud line 64 and provides selective communication between mud line 64 and mud return line 36 .
[0022] Water may be selectively delivered into water space 46 via a water supply line 76 ( FIG. 1 ) shown depending from vessel 22 and connecting to lift pump assembly 34 . Referring back to FIG. 2 , a water inlet lead line 78 has an end coupled with water supply line 76 and an opposing end attached with a manifold assembly 80 that mounts onto cap 52 . The embodiment of the manifold assembly 80 of FIG. 2 includes a connector 82 , mounted onto a free end of a tubular manifold inlet 84 , an annular body 86 , and a tubular manifold outlet 88 , where the inlet and outlet 84 , 88 mount on opposing lateral sides of the body 86 and are in fluid communication with body 86 . Connector 82 provides a connection point for an end of water inlet lead line 78 to manifold inlet 84 so that lead line 78 is in communication with body 86 . A lower end of manifold body 86 couples onto cap 52 ; the annulus of the manifold body 86 is in fluid communication with water space 46 through a hole in the cap 52 that registers with opening 50 . An outlet connector 90 is provided on an end of manifold outlet 88 distal from manifold body 86 , which has an end opposite its connection to manifold outlet 88 that is attached to a water outlet lead line 92 . On an end opposite from connector 90 , water outlet lead line 92 attaches to a water discharge line 94 ; that as shown in FIG. 1 , may optionally provide a flow path directly subsea.
[0023] A water inlet valve 96 shown in water inlet lead line 78 provides selective water communication from vessel 22 ( FIG. 1 ) to water space 46 via water inlet lead line 78 and manifold assembly 80 . A water outlet valve 98 shown in water outlet lead line 92 selectively provides communication between water space 46 and water discharge line 94 through manifold assembly 80 and water outlet lead line 92 .
[0024] In one example of operation of pump 38 of FIG. 2 , mud inlet valve 66 is in an open configuration, so that mud in mud return line 32 communicates into mud line 64 and mud lead line 68 as indicated by arrow A Mi . Further in this example, mud exit valve 74 is in a closed position thereby diverting mud flow into connector 70 , through opening 72 , and into mud space 44 . As illustrated by arrow A U , bladder 42 is urged in a direction away from opening 72 by the influx of mud, thereby imparting a force against water within water space 46 . In the example, water outlet valve 98 is in an open position, so that water forced from water space 46 by bladder 42 can flow through manifold body 86 and manifold outlet 88 as illustrated by arrow A Wo . After exiting manifold outlet 88 , water is routed through water outlet lead line 92 and into water discharge line 94 .
[0025] An example of pressurizing mud within mud space 44 is illustrated in FIG. 3 , wherein valves 66 , 98 are in a closed position and valves 96 , 74 are in an open position. In this example, pressurized water from water supply line 76 is free to enter manifold assembly 80 where as illustrated by arrow A Wi , the water is diverted through opening 50 and into water space 46 . Introducing pressurized water into water space 46 urges bladder 42 in a direction shown by arrow A D . Pressurized water in the water space 46 urges bladder 42 against the mud, which pressurizes mud in mud space 44 and directs it through opening 72 . After exiting opening 72 , the pressurized mud flows into lead 68 , where it is diverted to mud return line 36 through open mud exit valve 74 as illustrated by arrow A Mo . Thus, providing water at a designated pressure into water supply line 76 can sufficiently pressurize mud within mud return line 36 to force mud to flow back to vessel 22 ( FIG. 1 ).
[0026] As illustrated in FIGS. 2 and 3 , bumper 56 travels axially within housing 40 , and has end strokes proximate to the inner surface of housing 40 . An optional controller 100 ( FIG. 1 ) may be provided for limiting travel of bladder 42 and bumper 56 to avoid collisions of bladder 42 or bumper 56 with the inner surface of housing 40 . In an embodiment, controller 100 includes an information handling system, and receives or contains instructions to selectively operate valves 66 , 74 , 78 , 98 . Optionally, valves 66 , 74 , 78 , 98 can include actuators (not shown) in communication with and/or controlled by controller 100 , that manipulate the valves 66 , 74 , 78 , 98 to limit travel of the bumper 56 . The controller 100 can be set based upon an increase or decrease in fill volume that alters velocity of flow in one of the chambers 44 , 46 . User defined set points can be input to the controller 100 for establishing limits of travel of the bladder 42 . This can be manifested via control of the valves 66 , 74 , 96 , 98 so that they open and close at designated times and sequences so that travel of bladder 42 and/or bumper 56 prevents or avoids collision with housing 40 . Moreover, a set bias may be included with commands in the controller so that the control system automatically adjusts the set points to a higher or lower value to bring bladder travel within a safe range and thereby avoid any damaging contact. Examples exist wherein volume in one of the chambers 44 , 46 at a maximum stroke ranges from about 15 gallons to about 55 gallons. By setting the set points with an included bias, the set points are adjusted during use so that in a subsequent cycle of pumping, the extent of bladder travel is decreased to avoid any overshoot from a designated position.
[0027] FIG. 4 is a schematic illustration of an example of a lift pump assembly 34 having pumps 38 A-C arranged in parallel. In this example, and similar to that of FIG. 2 , mud flows to pumps 38 A-C respectively from mud lines 64 A-C that each have an inlet end connected to mud return line 32 . Outlet ends of the mud lines 64 A-C discharge into mud return line 36 . Leads 68 A-C respectively communicate mud flow between pumps 38 A-C and lines 64 A-C, where valves 66 A-C, 74 A-C respectively regulate flow through lines 64 A-C. In similar fashion, water from water supply line 76 flows to pumps 38 A-C via water inlet lead lines 78 A-C and manifold assemblies 80 A-C; and water from pumps 38 A-C is delivered to water discharge line 94 via manifold assemblies 80 A-C and water outlet lead lines 92 A-C. Water to and from pumps 38 A-C is controlled by valves 96 A-C and 98 A-C, which are shown respectively in lines 78 A-C and lines 92 A-C. Optionally, one or more of valves 66 A-C, 74 A-C, 96 A-C, 98 A-C, 106 A-C, 108 A-C may be in communication with a controller 100 for selective opening and/or closing the valves, or throttling flow through the valves.
[0028] The lift pump assembly 34 of FIG. 4 is equipped with a pressure balance circuit 102 for minimizing a pressure differential across valves 96 A-C. In the example of FIG. 4 , pressure balance circuit 102 includes pressurization tubing 104 A-C, each having inlets respectively connected to water inlet lead lines 78 A-C. Optionally, pressurization tubing 104 A-C can connect directly to water supply line 76 . Pressurization valves 106 A-C are provided within each run of pressurization tubing 104 A-C. Each run of tubing 104 A-C includes depressurization valves 108 A-C downstream of pressurization valves 106 A-C. Tubing leads 110 A-C branch respectively from pressurization tubing 104 A-C in the portions between pressurization valves 106 A-C and depressurization valves 108 A-C. The ends of tubing 110 A-C distal from pressurization tubing 104 A-C connect to water inlet lead lines 78 A-C downstream of inlet valves 96 A-C. In an example of operation, when water is being discharged from pumps 38 A-C, outlet valves 98 A-C are in the open position, and inlet valves 96 A-C are in the closed position, a pressure differential can exist across inlet valves 96 A-C that can approach pressure in water supply line 76 . Further in this example, opening valves 106 A-C, while valves 96 A-C and 108 A-C are in a closed position, communicates pressure from line 76 through pressurization tubing 104 A-C, tubing leads 110 A-C, and into inlet lead lines 78 A-C downstream of valves 96 A-C. In this example embodiment, fluid in lines 78 A-C upstream and downstream of valves 96 A-C is in pressure communication with line 76 , thereby minimizing pressure differential across valves 96 A-C.
[0029] Downstream of valves 108 A-C, pressurization tubing 104 A-C connects to a tubing header 112 , through which water in the pressure balance circuit 102 can be discharged to ambient. In the example of FIG. 4 , pumps 38 A-C and the associated piping disclosed herein are referred to as a pump module 114 A. Example embodiments exist wherein the lift pump assembly 34 includes two or more modules. As such, a water discharge line 116 from another module 114 B, that is substantially similar to module 114 A. Block valves 118 , 120 are respectively provided in discharge lines 94 , 116 for isolating water flow from modules 114 A, 114 B. Also in line 94 is an optional block valve 122 downstream of the intersection of line 116 with line 94 ; and a control valve 124 and flow meter 126 downstream of block valve 122 . An optional bypass line 128 connects tubing header 112 to water discharge line 94 between control valve 124 and flow meter 126 . A block valve 130 is shown in tubing header 112 downstream of bypass line 128 , and a block valve 132 is provided in bypass line 128 . In an alternative embodiment, block valves 130 , 132 are in communication with controller 100 .
[0030] Still referring to the example of FIG. 4 , line 94 discharges to ambient downstream of control valve 124 , thus depending on the flow rate of fluid in line 94 , pressure in line 94 downstream of control valve 124 is substantially equal to ambient pressure. In the illustrated embodiment, control valve 124 and flow meter 126 are shown in communication with one another, so that a flow area through control valve 124 automatically adjusts in response to a flow rate detected by flow meter 126 to “throttle” flow across control valve 124 . Optionally as shown, control valve 124 is in communication with controller 100 , so that the amount of throttling can vary based on operating conditions of the lift pump assembly 34 . As such, a pressure differential can be generated across control valve 124 so that pressure in line 94 upstream of control valve 124 is greater than pressure at ambient and introduces a backpressure in line 94 . Where the backpressure in line 94 suppresses flow rate spikes in lines 92 A-C, which in turn reduces cycling forces on components of pumps 38 A-C during pumping operations.
[0031] In some examples of use, pumps 38 A-C operate under “managed pressure drilling operations” where mud flow rates are reduced, but pressure of the mud to the pumps 38 A-C is increased. During these conditions, the flow path to ambient through the pressure balance circuit 102 and from lines 78 A-C can allow pressure in pumps 38 A-C to drop below a threshold value so that pumps 38 A-C will uncontrollably fill with mud during a subsequent pumping cycle. One example of operation to address the unacceptable pressure drop includes diverting flow in tubing header 112 that is being discharged from pressure balance circuit 102 through bypass line 128 . In this example, block valve 130 is set into a closed position and block valve 132 is open. In an optional example, controller 100 delivers instructions for opening/closing of the block valves 130 , 132 . As indicated above, bypass line 128 terminates into water discharge line 94 upstream of control valve 124 , which is maintained at a pressure sufficiently above ambient so that a backpressure can be exerted onto pressure balance circuit 102 . In the example of FIG. 4 , the backpressure on the pressure balance circuit 102 communicates to the water side 46 ( FIG. 2 ) of each pump 38 A-C; which maintains a minimum pressure in the water side 46 of each of the pumps 38 A-C to avoid an uncontrolled influx of mud flow into the pumps 38 A-C.
[0032] Referring now to FIG. 5 , an alternate embodiment of drilling system 10 A is shown in side partial sectional view and wherein lift pump assembly 34 A includes a mud pump kit 134 mounted integral onto riser 26 A. In this example, mud pump kit 134 includes a subsea module 136 shown circumscribing riser 26 A and that includes mud distribution manifold (not shown) and other flow control devices for selectively diverting flow to desired destinations. A riser module 137 is illustrated mounted on an upper surface of subsea module 136 , which also circumscribes riser 26 A. Riser module 137 of FIG. 4 includes controls for operation of the pump kit 134 , such as a processor 138 having hardware and software for controlling operation of components of pump kit 134 . Also included in riser module 137 are hydraulic power units 139 for providing pressurized hydraulic fluid, which in an example is used for actuating devices subsea, such as valves in pump kit 134 . Riser module 137 also includes hydraulic control systems connection hardware for mounting mud pump kit 134 to riser 26 A. Pumps 38 ( FIG. 2 ) are housed in pump modules 140 , 142 shown set on riser module 137 . In an embodiment, pump modules 140 , 142 each include three pumps 38 . In an example, included in the subsea module 136 is piping 143 that provides connectivity, and communication of mud flow, between the riser 26 A and pump modules 140 , 142 . Piping 143 further alternatively includes a circuit that connects to riser 26 A, but bypasses pump modules 140 , 142 . Examples of operation where pump modules 140 , 142 are bypassed include situations where pressure in the mud flow is sufficient for flowing to surface, or where pump module(s) 140 , 142 are not in service. In an example, valves 144 (that can be part of a valve kit) in the pump modules 140 , 142 are actuated and/or controlled by processor 138 , and may optionally be powered by hydraulic fluid supplied from hydraulic power unit 139 .
[0033] A solids recovery unit (SRU) 145 is shown above the pump modules 140 , 142 , and a subsea rotating device (SRD) 146 attaches to an upper end of SRU 145 . An upper end of SRD 146 flangedly attaches to a riser joint 148 ; where in one example a substantial portion of the riser 26 A between SRD 146 and vessel 22 ( FIG. 1 ) is made up of stacked riser joints 148 .
[0034] In the example of FIG. 4 , mud exiting drill string 20 flows upward in an annulus 150 defined between drill string 20 and wellbore 12 , and which extends further upward between drill string 20 and riser 26 A. The mud flows past mud pump kit 134 and SRU 145 within annulus 118 and into SRU 146 where a packer (not shown) blocks the mud. In an embodiment, the annulus 118 above packer is filled with sea water or other fluid. Mud within annulus 118 below packer is diverted to SRU 145 where cuttings or other solids are removed or particulated. After being processed in the SRU 145 , the mud is directed to the pump modules 140 , 142 where it is pressurized so it can flow back to vessel 22 . Processing the mud in the SRU 145 can prevent damage to the pumps 38 ( FIG. 2 ) in the modules 140 , 142 .
[0035] In an example, modules 136 , 137 , 140 , 142 are modular elements that can be transported separately to the vessel 22 ( FIG. 1 ) on site, where the pump kit 134 is assembled. Still referring to FIG. 1 , a vessel 152 , which in an example is smaller than vessel 22 , is shown transporting a module 136 to vessel 22 . Optionally, embodiments exist where none of the modules 136 , 137 , 140 , 142 weigh in excess of 50 metric tons. A maximum weight of 50 metric tons is advantageous as this is the upper weight capacity of most barges. In alternatives where the weight of each of modules 136 , 137 , 140 , 142 does not exceed 50 metric tons, any one of modules 136 , 137 , 140 , 142 can be individually transported to vessel 22 with vessel 152 . A significant time savings is one advantage of the modularity of modules 136 , 137 , 140 , 142 . Due to the weight of the pump kit 134 , and that the pump kit 134 asymmetrically loads an offshore rig or vessel 22 , which requires anchoring and stabilization, loading a fully assembled pump kit 134 onto a vessel 22 is impractical. Whereas vessel 152 can transport the modules 136 , 137 , 140 , 142 individually, and vessel 22 can accommodate individual modules 136 , 137 , 140 , 142 on site and without becoming unstable.
[0036] In an optional embodiment, pump modules 140 , 142 are individually detachable from the pump kit 134 , and thus further enhancing modularity of the pumping system. Dedicated piping (not shown) may be routed from SRU 145 and separately to each module 140 , 142 so that one of the modules 140 , 142 can remain operational while the other is removed or otherwise out of service. Further, spare modules can be kept on site for one or both modules 140 , 142 , and can installed in place of a one of the modules 140 , 142 with little or no stoppage of operation of pumping mud to the vessel 22 .
[0037] Yet further optionally, BOP 28 A is a BOP stack, whose upper portion includes an annular blowout preventer and is part of a lower marine riser package (LMRP). Additionally, LMRP can include controls, a multiplexer unit, and pods. In an embodiment, modules 136 , 137 , 140 , 142 , SRU 145 , SRU 146 , BOP 28 A, and riser joints 116 are delivered to the vessel 22 ( FIG. 1 ) while on site and disposed above wellbore 12 . While on the vessel 22 , modules 136 , 137 , 140 , 142 are attached together to form mud pump kit 134 which is coupled with BOP 28 A. SRU 145 and SRU 146 are attached onto mud pump kit 134 ; while suspended from riser joints 116 the assembled unit is lowered subsea onto wellhead housing 30 .
[0038] Referring now to FIG. 6 , shown in a perspective view is a schematic example of a mud pump kit 134 mounted onto a riser 26 A. As shown, pump modules 140 , 142 are stacked respectively on starboard and port sides of riser 26 A and on top of riser module 137 ; where riser module 137 stacks on top of subsea module 136 . As illustrated in FIG. 6 , mud return line 36 shown including a fitting 156 between where mud return line 36 couples with riser 26 A and the pumps 38 A-C. Fitting 156 can be a flanged surface, a valve, or any other device for fluidically coupling sections of a line. In this example pump modules 140 , 142 are symmetric to one another so that pump module 140 can be switched out for pump module 142 (and vice versa). Thus the corresponding mud return line (not shown), provided with pump module 142 and for pumps 38 D-F, is oriented to mate with fitting 156 . The symmetric/mirror image configuration of pump modules 140 , 142 allows one of the pump modules 140 , 142 to be switched out for the other without rearranging any piping. An advantage of this design is that only a single spare pump module 160 need be stored onsite, which can be used to replace either of pump module 140 or pump module 142 .
[0039] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
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A method and system for lifting drilling mud from subsea to a drilling vessel, which uses a pump having a body with a chamber, and a bladder in the chamber. The bladder attaches to the body and defines water and mud sides in the chamber. A mud inlet valve allows mud into the mud side of the chamber; which moves the bladder into the water side and urges water in the water side from the chamber and through a water exit valve. Pressurized water enters the chamber through a water inlet valve, which in turn pushes the bladder and mud from the chamber through a mud exit valve. The bladder separates the mud and water as it reciprocates in the chamber. The travel of the bladder in the chamber is controlled to prevent damage from contact with the chamber.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a needle thread guide device with a vertically oscillating thread lever in a sewing machine provided with a skip stitch mechanism which works at intervals. More particularly the present invention is directed to a needle thread guide device on a sewing machine with a skip stitch mechanism working at intervals for forming stitches with varying lengths, utilizing a continuously driven, vertically oscillating thread lever.
Sewing machines of the general type described above are known. The thread lever and its eye, usually driven by a crank, oscillate in time with the needle shaft drive in a vertical plane along a closed curve with an upper and lower reversal point. Its needle shaft is controlled to produce stitches with varying lengths at intervals so that stitch formation is suspended. During the skip stitch interval, i.e. when the stitch formation and thread use are suspended, the thread lever continues to perform its function of supplying the necessary length of thread needed to form a stitch. A relatively large thread reserve is built up during each skip stitch interval between the thread tensor and the needle. The thread does pass through the thread lever eye but otherwise forms a completely free, i.e. slade thread loop. This is particularly true in those situations in which the skip stitch mechanism temporarily disengages the needle shaft from the drive device when the stitch is skipped and holds it stationary in its upper end position. The thread loop formed in this case does not remain still despite the fact that the needle stands still while the thread lever continues to run and can, in unfortunate situations, become tangled around parts of the machine, or both parts of the thread can become entangled.
Accordingly an object of the present invention is to avoid these disadvantages by providing that the excessive length of thread produced by skipping a stitch, in which the thread lever continues to feed in thread during its first empty stroke and forms this thread loop between the needle eye and the thread tensor, is held nearly taut, at least long enough for the normal thread consumption required by normal stitch formation to be initiated again.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood 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 this end, the needle thread guide device according to the present invention is characterized by a thread lever having a thread catcher which can be engaged and disengaged synchronously with the skip stitch mechanism and which, in its operating position, aligns with a hook eye, open at the top, at a position in the upper area of the upward path of the thread feeder eye, in order to take up the thread loop carried along by the thread lever. The thread lever then continues moving downward without the thread, i.e. the latter remains nearly taut between the thread catcher and the needle. The thread catcher hook is constricted so that when the thread lever subsequently moves upward, the thread lever eye moves up beyond the hook eye of the thread catcher to the upper reversal point picking the thread up in the process and removing it from the hook eye in order to replace it in the catcher hook of the thread catcher with the next downward movement of the thread lever, provided of course, that the thread lever remains in its operating position as a result of the corresponding position of the skip stitch mechanism. Of course the thread catcher is disengaged at any point along the thread lever path at which the thread is removed from the thread catcher.
The thread catcher is advantageously a double lever which pivots around a stationary axis in a plane parallel to the pivoted plane of the thread lever, the latter being operationally connected under spring tension to a lever. Said lever activates the skip stitch mechanism and can be activated in turn by a control device which determines the skip stitch interval. This device can be a cam, a step motor, or any other suitable interval control device.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed 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 shows a top view of a needle thread guide device on a sewing machine with a thread feeder lever, a thread catcher interval control cam for a thread catcher and a skip stitch mechanism;
FIG. 2 shows a vertical section along line II--II of FIG. 1;
FIG. 3 shows a side view of FIG. 1 with the thread catcher hook eye in operating position aligned with the thread lever eye;
FIG. 4 shows a view according to FIG. 3 with the thread lever pivoted in the upward direction, and
FIGS. 5, 6 and 7 each show a side view of the thread lever and the thread catcher illustrating various relative positions of the eyes of two levers.
DETAILED DESCRIPTION OF THE INVENTION
In the drawing the customary machine arm housing has the reference numeral 1. The drive apparatus, not shown in any more detail, and the skip stitch mechanism, as well as the guide device for the needle thread 3 are located in the head part of the housing. The machine parts which are of no specific importance in connection with the present invention are not described in any more detail hereinbelow. This applies as well to the skip stitch mechanism. The illustrated example of said mechanism corresponds with the detailed description in the Swiss patent application (G 6621/79) which corresponds to a companion U.S. application Ser. No. 167,102 filed July 9, 1980, now U.S. Pat. No. 4,359,954.
The thread guide device of the illustrated machine has a two-armed thread lever 4 which is attached to a connecting rod 5 which in turn is pivotingly attached to a stationary axis 6. The one arm 4a of the thread lever 4 is connected to a drive crank (not shown) while the other arm 4b has the customarily bent slot 4d which ends in a round eye 4c and is formed by the thread lever extension. The skip stitch mechanism found here, for example, has a program element in the form of a cam which determines the skip stitch intervals. A feeler lever 9 which is engaged and disengaged by hand through a button 8 follows the program element cam in operating position (FIG. 3). It either engages or disengages the carrier 11 for the needle shaft 2 by way of an appropriate lever mechanism 10a, 10b and simultaneously either engages or disengages a catch 12 which holds the needle shaft in its uppermost end position. Such a skip stitch mechanism, which is more closely described in the Swiss patent, is in its topmost end position in which the lever allows the needle shaft 2 to couple with its drive, while at the same time the extension arm 13 of lever 10a holds the thread catcher lever 14 against spring tension in the disengaged, pivoted position as shown with dotted lines in FIGS. 5, 6 and 7. The needle thread 3, carried along the eye 4c of the thread lever, is oscillatingly swung by the thread lever, which is driven synchronously with the needle shaft, for the purpose of supplying the lengths of thread needed to form stitches. The path covered by the thread lever eye 4c is designated, a, b in FIGS. 5, 6 and 7, and forms a self contained curve with an upper and lower reversal point. If the skip stitch is engaged by means of the button 8 the feeler lever 9 follows the program curve of the cam 7. If the feeler lobe of the feeler lever 9 is located on the radially higher part of the curve, this corresponds exactly to the aforementioned operating position of the individual elements for normal sewing, i.e. stitches are formed, and the thread catcher lever 14 is disengaged. On the one hand, if the feeler lobe of the feeler lever 9 moves onto the radially lower curve part, the needle shaft 2 is disconnected and stopped in its upper movement region by the catch 12 (FIG. 3) while, on the other hand, the thread catcher lever 14 is returned by spring tension to its operating position shown with solid lines in the drawing. In this position the eye 14c is aligned with one position of the upper portion of the upward reaching branch b of the movement path of thread lever eye 4c. After passing the upper reversal point, the thread eye 4c, carrying the needle thread 3, moves along down branch b of its movement path where the thread 3, carried along by it, is caught by the hook of the thread catcher lever 14 and held in the eye 14c, while the eye 4c of the thread lever moves further along down the extended thread portion. The length of thread pulled from the supply spool by the thread lever over the thread tensor, which is not pulled down by the needle due to the interruption of the stitch formation, remains stretched between the needle eye, the thread catcher eye 14c, the thread lever eye 4c and the thread tensor. Without this thread catcher, the thread loops between the thread tensor and the needle eye, caused by the thread lever 4 moving up and down, would oscillate between a slack and a taut condition (see 3a of FIG. 4). Such an uncontrolled oscillating of the thread loops is, as was stated above, avoided when the skip stitch mechanism is engaged by the thread catcher lever 14. The thread lever eye 4c which, after its downward movement, again follows the upward branch a of its movement path, lifts the needle thread 3 out of the hook of the thread catcher lever 14 again when it passes close by the eye 14c of the thread catcher 14 (FIG. 5). If the feeler lobe of the feeler lever 9 also remains on the lower part of the curve of the cam 7 for the next skip stitch cycle, i.e. the thread catcher lever 14 remains in its operating position, the needle thread 3 is hung again in the hook of the thread catcher lever 14 with the recurring upward movement of the thread lever, and the eye 4c, respectively. The thread loop is then drawn taut and held again. If, however, the feeler lever 9 has run onto the raised part of the curve on cam 7, this means not only that the needle shaft 2 is engaged and the catch 12 is disengaged, but also, by pushing the lever 14 up by means of the extension arm 13 of lever 10a, the thread catcher lever 14 is pivoted against spring tension simultaneously into its disengaged position. The result is that when the thread lever eye 4c goes down again, the needle thread passes unimpeded through the hook of the thread catcher lever 14. Normal stitch formation and consumption of fed-in excess thread results again when the needle shaft 2 goes down.
Of course the described thread catcher lever 14 associated with the thread lever 4a, b, c in no way anticipates the described skip stitch mechanism. The important point is that the thread catcher lever and the skip stitch mechanism are synchronously engaged and disengaged.
Thus, according to the present invention the needle thread guide device has an articulated thread lever 4, whose eye 4c, carrying the needle thread 3, follows a closed movement path a, b with an upper and lower reversal point. The skip stitch mechanism, which interrupts the stitch formation at intervals, is controlled by way of a lever mechanism 10a, 10b and a feeler lever 9 which can be engaged and disengaged by means of a cam 7. The cam controls a skip stitch mechanism which interrupts normal stitch formation at intervals by way of a lever mechanism and a feeler lever which can be engaged and disengaged. A lever 10a of the lever assembly 10a, 10b also simultaneously activates a thread catching lever 14. This rotates around a stationary axis in a plane parallel to the movement plane of the thread lever 4. In its operating position, which corresponds to the situation in which the skip stitch mechanism is engaged, a hook eye 14c of the thread catcher lever 14 is aligned with the upper part of the descending branch b of the movement path of the thread lever eye 4c. When the thread lever eye 4c goes down, the needle thread 3 is temporarily hung in the eye 14c of the thread catcher lever 14. The thread loop formed as the needle thread 3 continues to be pulled in when the thread is not used a result of the skipped stitch, is held taut preventing this loop from being moved around loosely by the thread lever's 4 up and down movement. By switching the skip stitch mechanism off, the thread catcher lever 14 is simultaneously disengaged.
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 as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A needle thread guide device containing an articulated thread feeder oscillating in a vertical plane on a sewing machine provided with a skip stitch mechanism working at intervals to form stitches of varying lengths, wherein a thread catcher is combined with a thread lever which can be engaged and disengaged synchronously with the skip stitch mechanism and which aligns in its operating position with a hook eye open to the top at a position of the upper area of the ascending movement part of the thread lever eye with the latter, thereby catching the thread loop which is carried along by the thread lever.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This U.S. patent application is a division of prior U.S. patent application Ser. No. 10/455,491, filed Jun. 4, 2003, which application claims priority to provisional patent application 60/386,519, filed Jun. 5, 2002, the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to systems for supporting and laterally equalizing the temperature of surfaces during heating processing steps, and more particularly to systems for equalizing temperatures across the surface of large area semiconductor wafers.
[0003] The development of semiconductor processing technology has consistently tended, for economic and technical reasons, to use increasingly larger semiconductor wafers, in order to multiply the number of individual patterns that may be disposed on the surface of the wafer and thus processed concurrently. In the current state of the art equipment is now in use for processing wafers of 300 mm in diameter. Wafers of this size present problems not heretofore encountered, as to assuring uniformity of the individual patterns in the array wafer. Fabrication phases begin with pattern deposition sequences typical of those employed in photomicrolithography, after which semiconductor layers are formed by high energy processes, such as plasma etching or ionic bombardment. Different phases are carried out until all layers have been deposited. The wafer, enclosed within a chamber having the needed environment, such as a gas or vacuum, is supported on a pedestal or chuck configured to hold the wafer firmly while slowing temperature buildup at the wafer. The total amount of thermal energy to be removed from the wafer may be of the order of several kilowatts, so that it is to be expected, with a 300 mm wafer, that temperature across the surface of the wafer will not be uniform.
[0004] Modern semiconductor fabrication equipment employs many process steps in which semiconductor wafers advance progressively to different fabrication tools, usually by robotic handling systems. Positioning, retention and often temperature control of the wafers can be critical because of the very demanding precision involved and the need for high throughput with maximum yield. Wafer supports, often called chucks or platens, now hold the wafer firmly by such means as electrostatic attraction and also cool the wafer itself, as by circulating a heat conductive inert gas (e.g. helium or argon) between the opposed faces of the wafer and the pedestal on which it rests. For the latter purpose, a relief pattern in the pedestal (or platen) surface provides gas flow paths in contact with the wafer, and interior conduits in the pedestal facilitate circulation of the heat transfer gas into the limited interspace between the opposing surfaces. Examples of such systems are U.S. Pat. No. 6,320,736 to Shamoulian et al, No. 6,315,828 to Paladia et al, No. 6,310,755 to Kholodenko et al and No. 5,748,435 to Parkhe. The Shamoulian et al patent points out that certain geometrical factors can cause variations in heat transfer rates across the substrate, and that different parts of a substrate (wafer) surface can result in different heat loads at different parts of the surface. It proposes the use of different pressures of heat transfer gas across the broad side of the substrate to counteract zonal variations, these to be obtained by the use of non-sealing protrusions of selected shapes.
[0005] As wafer sizes increase, however, as with 300 mm diameter wafers now being produced, local and/or lateral temperature variations cannot readily be compensated by such techniques. The heat transfer gas flowing in the interface spaces is not readily capable of equalizing temperatures laterally as well as extracting thermal energy. The likelihood of lateral variations in temperature is increased markedly with larger wafers, because area increases as the square of the radius.
[0006] The semiconductor wafer processing context is particularly demanding in terms of technical requirements and economic benefits. Other applications for lateral temperature equalization exist, however, and the present disclosure may be of benefit in these situations as well.
[0007] Various types of heat transfer devices are known and used in particular refrigeration applications. Standing alone, these devices have potential for meeting specific individual needs, but they do not suggest a solution to the lateral equalization problem presented by large semiconductor wafers. The heat pipe, for example, is based upon the use of a permeable or wicking material which retains a somewhat mobile heat transfer fluid in thermal equilibrium with its surroundings. By equilibration of liquid and vapor phases, thermal energy is absorbed in accordance with the heat of vaporization, following which vapor that is generated can readily migrate to a separate cooling area, to condense and be transported back, by the wicking action, to the region at which heat is being absorbed.
[0008] Another device that uses boiling and condensing is a “reflux” type of cooling system, which employs gravitational flow to return the condensate to the needed location in the system. Although a number of reflux devices are known, such devices do not suggest solutions to the problem of equalizing the temperature of a large semiconductor wafer that is being cooled.
[0009] The driving force in the basic heat pipe is the tendency of a liquid to wick through finely divided surfaces such as meshes or felts. Heat pipes first found application in the zero gravity environment of outer space, since wicking action is independent of gravitational force.
[0010] The main problem with applying heat pipes in systems that need tight coupling of heat source to sink is their difficulty in transferring large amounts of heat over long distances. The pressure pulling a liquid along a wick is inversely proportional to the interstitial distance between fibers or wires in the wick. Unfortunately the pressure drop undergone by the liquid as it travels along the wick is inversely proportional to the same distance squared. The balance between surface tension pressure driving the liquid phase in the wicking process and the pressure drop in the liquid means that there is an optimum mesh fineness for any heat pipe boundary condition. It also means that there is a limit to the distance that a given area of wick can transport an amount of heat with a given temperature difference. The controlling equations that govern these relationships are set out in texts, as for example, Dunn, P. D., “Heat Pipes”, Third Edition, Pergamon Press, 1982.
SUMMARY OF THE INVENTION
[0011] In accordance with the invention, for the semiconductor processing application a chuck upon which a large area semiconductor wafer rests includes a pedestal surface coextensive and in thermal contact with the underside of the wafer, an intervening lateral temperature equalizing structure, and an underlying base or cathode structure. The lateral temperature equalizing structure is within a relatively small vertical gap between the pedestal surface and the upper side of the base or cathode. The underside of the pedestal is in contact with a layer of wicking material from which short lengths of wicking columns depend. The depending columns are distributed a really in a closely spaced pattern throughout the underside of the wicking layer and substantially coextensive with the wafer. The temperature equalizing structure occupies a volume which confines a pool of selected heat transfer fluid, such as ammonia, alcohol or water, into which the lower ends of the wicking columns extend without contacting the floor. A number of condenser fins, or posts, extend upwardly through the liquid from the floor, which constitutes the upper surface of the base, but do not contact the upper wicking layer. The condenser posts are interdigitated among the depending wick elements. The condenser posts, which may themselves be wicking elements, are sites for collection of condensate from vapor generated by heat transfer. The interfacing thermal transfer gas under the wafer extracts some thermal energy out, and also convects some to the pedestal layer, which in turn transfers thermal energy within the lateral temperature equalization structure.
[0012] The underlying wicking layer and the spaced apart short wicking columns are spaced so that they are in close thermal coupling relation to all areas of the wafer. Higher temperature at any localized area of the wafer causes rapid stabilization of temperature in that area because of the proximity of sites at which vaporization occurs to one or more wicking posts and the interspersed condensation posts. All the posts have short path lengths to the pool of thermal transfer fluid. Gravitational forces are such that, given the shallow liquid pool, liquid will flow readily with exceedingly small changes in head. This action forces a high lateral heat flow if any temperature differences come into existence. Vapor movement occurs readily as well since there is little to impede flow of vapor in the lateral direction.
[0013] In a more particular example of a system in accordance with the invention, the wicking assembly on the top of the chamber is formed as a horizontal array of sintered metal plugs having intermeshed hexagonal caps or upper surfaces, and depending short wick posts or columns depending from the underside of the cap. At the lower half of the chamber, the condensation assembly is formed as an array of hexagonal conductive plugs with upstanding posts, interdigitated relative to the short wick elements as described above. A patterned sheet metal spring element fitted between the two assemblies has holes through which the upstanding conductive plugs can extend, and contains individual leaf springs formed therein which contact the underside of the depending wicking elements. The sheet metal spring plate thus both holds the conductive plugs in position under downward pressure, and urges the sintered metal plugs upwardly to maintain contact with the underside of the pedestal. In addition, the temperature equalization structure can be reinforced across its surface by strengthening posts which can support the pedestal against gas pressures and provide conduits for thermal transfer gases, wafer removal pins and the like which can function to aid removal of the wafer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A better understanding of the invention may be had by reference to the following description, taken together with the accompanying drawings, in which:
[0015] FIG. 1 is a simplified perspective view, partially broken away, of a wafer retention system including a lateral temperature equalization structure in accordance with the invention;
[0016] FIG. 2 is a simplified side sectional partial view of a lateral temperature equalization structure in accordance with the invention, showing further details thereof;
[0017] FIG. 3 is a simplified example of a wicking structure, useful in explaining the operation thereof;
[0018] FIG. 4 is a graph of heat flux variations in relation to temperature difference, illustrative of the operation of a heat pipe and wicking structure;
[0019] FIG. 5 is an exploded perspective view of a more specific example of heat transfer structure in an equalization unit in accordance with the invention; and
[0020] FIG. 6 is a side sectional partial view showing the assembly of the elements depicted in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] A system in accordance with the invention, referring now to FIG. 1 , is compatible with and complementary to electrostatic chuck systems of the type generally described above. While the system may be employed with any size wafer (substrate), it is uniquely adapted to resolving the critical heat distribution problems encountered with the large 300 mm diameter wafers. The example of FIG. 1 depicts a 300 mm semiconductor wafer 10 in a process chamber 12 , indicated only by dotted lines, in which a high energy etching step, such as plasma etching, is to be effected. No disclosure of a specific example or details are needed, as to the wafer holding structure, in view of the state of the art. The electrostatic chuck device 14 on which the wafer 10 is precisely mounted comprises a cathode base 16 that is charged in a desired polarity by a voltage source 17 , and an uppermost pedestal (also sometimes called a chuck or platen) 20 with a surface 21 having patterned depressions, such as grooves 23 , including apertures for circulating an inert heat transfer gas (helium or argon) through the small interspaces between the upper surface 21 of the pedestal 20 and the underside of the wafer 10 . After the gas is fed in at a port 24 , it flows through the available spaces until it is extracted at another port 25 . More specific examples or descriptions are not included because they may be found in the patents referred to above and others.
[0022] The dynamics of a high energy process procedure such as plasma etching, as they affect the wafer 10 surface, vary with time and a real distribution as the procedure is carried out. For example, the wafer 10 and chuck 14 are initially refrigerated to the lowest value (e.g. −30° C.) in an acceptably non-damaging range, and the process procedure (e.g. plasma heating) increases the temperature with time until a maximum acceptable upper limit (e.g. 70° C.) is reached. The thermal energy transferred from the wafer 10 to the pedestal 20 through the circulating heat transfer gas provides one restraint on the rate of temperature increase as thermal energy is constantly extracted. Another restraint on temperature increase is a static or dynamic heat exchanger or sink 29 coupled to the cathode base 16 , but together these cannot substantially extend the useful time span during which acceptable process temperatures exist at the wafer. Furthermore, the suggested modification of the local flows of the heat transfer gas is the only avenue by which temperature variations across the wafer 10 can be counteracted, and as noted these expedients cannot readily suffice for the much greater temperature disparities encountered with 300 mm (and larger) wafers.
[0023] In accordance with the invention, the chuck 14 is configured to include a lateral heat distribution or equalization structure 30 immediately below the pedestal 20 . The equalization structure comprises a chamber or volume with a roof and floor separated by a relatively low elevation. Reference is made here to FIG. 2 as well as FIG. 1 . A layer of wicking material 32 is coextensive with the underside area (roof) of the top of the pedestal 20 . The wicking material may be of sintered metal, woven or non-woven fabric, or other porous or permeable material capable of sustaining wicking action (i.e. migration of liquid against gravitational forces). An array of depending wicking posts 34 are spatially dispersed, here in a pattern of closely spaced geometry, throughout the area of the wicking material 32 . Although the posts 34 are short, they cumulatively provide a high surface area for vaporization, and their lower ends are immersed in a pool of thermal transfer liquid 36 (shown only in FIG. 2 ) which is confined within a peripheral barrier 37 on the upper side of the base at cathode 16 . The thermal transfer liquid 36 is advantageously from the class of liquids having relatively low evaporation points and viscosity, such as ammonia, alcohol or distilled water. A separate array of condenser fins or posts 38 extends upwardly from the liquid pool 36 , in regularly interdigitated relation to the depending wicking posts 34 . The fins 38 serve to provide a large net area of relatively cooler condensate collector for vapor in the interior volume. For clarity, the view of FIG. 1 shows a lower concentration of posts, and therefore a greater separation between them, than will usually be employed in practice. The relative displacements between the interdigitated elements that are shown in FIGS. 2, 5 and 6 are more indicative of the spatial relationships to be used in functioning units. The pedestal 20 is supported in this example against forces exerted during operation by a number of a really distributed and somewhat larger posts 41 , here called “strength posts”, although these or similar interspersed elements may alternatively be used for other purposes.
[0024] The lateral temperature equalization system 30 enables use of heat pipe technology in distributing heat uniformly over a short distance in combination with the ability of a reflux system to transfer heat rapidly with the aid of gravitational forces.
[0025] It achieves this by utilizing the equivalent of an assemblage of many heat pipes with a common reservoir of vapor-phase and liquid-phase thermal energy supply and sink sources. In FIG. 2 the fluid 36 layer is seen to be confined within the volume limited by the planar top wall of the cathode 16 , the bottom wall of the top pedestal 20 surface, and the peripheral barrier 37 . The thus enclosed heat exchange fluid 36 , in thermal equilibrium with the surroundings, is composed of liquid and vapor phases in balance with each other. The wicking material of the top layer 32 and depending columns 34 is soaked with the liquid phase of the fluid and the vapor phase occupies the interior of the volume. Heat injected at any surface with which the wicking layer 32 is in thermal contact transfers that heat to the liquid in the wicking elements 32 , vaporizing the fluid in the process of absorbing heat energy. The boiled off vapor flows to any cool area, such as the liquid pool 36 or condenser fins 38 where it condenses back to liquid. Heat will then be transferred to the heat exchanger or sink 29 outside the lateral equalization unit 30 . The condensed liquid then wicks to the surface area where heat is being absorbed and the process continues in a closed cycle with no outside control or effort being needed.
[0026] This solution to the distance problem and the heat transfer difficulty enables the length of operative wick to be kept short but always in close thermal coupling. By so doing it is possible to pass enough fluid through the wick while keeping the cross sectional area of the wick small enough to allow adequate heat to pass through without encountering burnout. In accordance with the invention, as shown in FIGS. 1 and 2 , the wick distance is kept short by employing a large number of separate wick assemblies. These are shown in FIG. 2 as a continuous length of wick 32 folded to form the depending posts 34 which dip, in short-distance intervals, into the pool 36 of liquid at the lower extremity of the internal volume. The storage of liquid in the pool allows ready transfer of the liquid from one side to the other to occur thereby augmenting the transverse thermal conductance of the system. The condensing surfaces consist of the plurality of standing posts or condenser fins 38 which are in thermal contact with the cathode or base 16 surface at their lower end and protrude for a short length above the surface of the liquid 36 .
[0027] The balance between pressure drop and wicking force means that it is difficult to use heat pipe techniques to transfer heat over long distances. As the distance between heat source and sink increases, the wick area needed for a given power level increases rapidly. As the power to be transferred increases the wick area also needs to grow. Thus a wick assembly designed to absorb power over a large area should have a large cross section for flow. This large cross-sectional area causes trouble for systems that need tight coupling between heat transfer surfaces and the boiling or condensing fluid. These transfer processes are illustrated in somewhat idealized form in FIG. 3 for an interface between a heat transfer surface 43 and an overlying wick 45 .
[0028] In FIG. 3 , the supportive boundary 43 , (“Heat transfer surface”) transfers heat to a “Wick” 45 , filled by “liquid” whose upper surface is shown. If a relatively large amount of heat flux is transferred (ca. 1-10 w/cm 2 or more) the process results in bubbles (“Vaporized bubbles”) being boiled off within the wick 45 . This can cause problems with heat flux near the limit. The boiled vapor can completely fill the wick volume and prevent proper heat pipe action completely. When this occurs the heat transfer from the surface is almost completely stopped and a ‘burnout’ condition is reached.
[0029] ‘Burnout’ is a phenomenon that is encountered in any type of heat transfer between a surface heat source and a boiling fluid. The general characteristics are shown in FIG. 4 , wherein the various domains of boiling transfer are notated by letters ‘A’ though ‘F’. From A to B heat will be transferred by natural convection. Evaporation of the fluid will only occur at the surface between liquid and vapor. In the range of B to C bubbles form at active nuclei on the heat transfer surface and rise through the pool of liquid to transfer heat via nucleate boiling. In this domain heat flux transferred varies as ΔT n where n varies from 3 to 4. At point C the heat flux goes through a maximum, or peak heatflux, at a temperature called the “critical ΔT”. In the range from C to D where part of the heat transfer surface is insulated by a vapor film, heat flux decreases as ΔT increases. At point D heat flux passes through a minimum at the “Leidenfrost point”. At this point and at higher temperature differences between heat transfer surface and liquid a film of vapor effectively insulates the liquid. In the film boiling regime from E to F heat is transferred through the vapor film by conduction and radiation. Point F, called the burnout point is the maximum temperature that can be reached by the particular apparatus employed for the measurement: typically the melting point of an electrical wire used as heat source.
[0030] There is a fundamental difference when a wick is introduced in the boiling interface. In the region B to C in FIG. 4 the heat transfer coefficients tend to be higher than they are in a planar surface interface; probably because of the higher tendency to form nuclei within the interstices of the wick. Point C however occurs at a lower heat flux level due to the blanking off of the wick when bubbles substantially fill the wick volume thereby preventing further flow of liquid to the heat transfer surface.
[0031] When a vapor condenses on a surface that is colder than the vapor's dew point the heat transfer is computed generally in the form of the equation:
h m =KΔT p /( L n )
where: h m =standard heat transfer coefficient
[0032] K is an empirical constant
[0033] L is the vertical length of a heat transfer surface
[0034] ΔT≡temperature difference between vapor and condensing heat sink surface
[0035] n and p are empirical exponents; typically around ¼ to ⅓
[0036] The above equation evinces mathematically that it is useful to employ a number of short fins rather than a single long fin. The typical mechanism encountered in condensing heat transfer is film condensing wherein the vapor is insulated from the fin by a film of condensate that is flowing away from the heat transfer surface under the influence of gravity. Dropwise condensation, wherein the vapor condenses and flows away from the heat transfer in droplet form is somewhat more powerful than film condensation but it is harder to maintain this heat transfer mode in a stable manner.
[0037] In a practical example, referring now to FIGS. 5 and 6 , the wicking body is fabricated in the form of small sintered metal plugs 50 , each formed into a shape that is generally analogous to a thumbtack having a hexagonal head 52 and a post 54 extending from it. These plugs 50 are assembled with interengaging heads 52 to form a wicking layer as shown in FIG. 5 with a regularly spaced array of depending posts. The condensing fins (“conductive plugs”) 60 are fabricated, in similar shapes with hexagonal heads 62 and perpendicular posts 64 , and can be of a material with a high thermal conductivity such as copper or aluminum. Alternatively the conductive plugs 60 can be fabricated of sintered copper if the combination of wicking and condensing is more efficient at condensing the particular liquid used. The plugs 60 are also assembled with interlocking heads 62 to form a planar body, and disposed in opposition to the metal plugs 50 so that the wicking posts 54 and condensing posts 64 are interdigitated but not in contact. A sheet metal spring 70 is placed between these two assemblages and serves to keep all of the separate elements tightly forced in opposite directions against their respective heat transfer surfaces. An array of circular holes 72 in the sheet metal spring 70 are spaced to receive the individual upstanding posts 64 , while adjacent finger springs 74 contact the depending sintered metal plug posts 54 to maintain the oppositely directed forces on the components of the assembly.
[0038] FIG. 6 also shows one of the strength posts 41 that reinforces the upper and lower walls surrounding the assembly. These horizontal walls also vertically confine the liquid and vapor that fills the interior volume of the temperature equalization unit. At higher temperatures the vapor pressure of the liquid used can reach fairly high pressures-ca. 60-70 atmospheres. The strength posts 41 are able to support the forces generated by such pressures. Some of the conductive plugs and also some of the sintered metal plugs may be specially shaped to accommodate as many strength posts placed at intervals as needed.
[0039] The strength posts 41 , or similar interspersed elements, can incorporate conduits for any facilities needed by an electrostatic cathode such as gases used to transfer heat from wafer to chuck or lifting pins to separate wafer and chuck after processing. These details are best defined by those familiar with a particular chuck design.
[0040] For an estimate of the effectiveness of the concept, assume a system of cooling a load of 2 kw evenly distributed across a pedestal surface about 300 mm in diameter. This gives a heat flux of about 2.4 w/cm 2 . It will be assumed that this load is cooled by a flow of heat exchanger liquid that heats up 10° C. as the liquid moves from one side of the chuck to the other. The temperature of the pedestal will be examined under these conditions. The wafer will be assumed to transfer heat into the pedestal across a free molecular barrier of helium gas at a pressure of 25 torr. The liquid flowing across the chuck is assumed to be “Galden HT 110” flowing in a heat transfer passage of about 0.5 cm×0.5 cm in extent.
[0041] Overall assumed parameters are:
[0042] AP# 1 . Fluid flow=2 gpm (gives approx 10° C. rise in temperature).
[0043] AP# 2 . Temperature of flow input=−10° C.
[0044] AP# 3 . Length of heat transfer passage=100 cm.
[0045] AP# 4 . Effective thickness of chuck=3 cm aluminum.
[0046] AP# 5 . Heat pipe material used is ammonia.
[0047] Calculated parameters are:
[0048] Heat transfer coefficient from chuck to wick=0.5 w/cm 2 °K( 1 extrapolated from water @ 2 atm.) 1 McAdams, William H., Heat Transmission, 3 rd edition, McGraw-Hill Book Co., Inc., New York, 1954, p. 382.
[0049] Heat transfer coefficient from Galden to surface of heat exchanger (based on heat exchanger surface area)=1.7 w/cm 2 ° K. 2 AP32.
[0050] Heat transfer coefficient from Galden to surface of heat exchanger (based on pedestal; 300 mm dia. surface area)=0.48 w/cm 2 °K.
[0051] Temperature differences associated, at full load of 2 KW are:
[0052] CPT# 1 . ΔT=13.9°
[0053] CPT# 2 . ΔT=5°
[0054] CPT# 3 . ΔT=2.5°
[0055] CPT# 4 . ΔT=4.2°
[0056] For purposes of this calculation it will be assumed that all heat flows occur in steady-state and continue indefinitely. In actual fact the wafer/chuck assembly undergoes a transient cool-down/heat-up cycle with each wafer processing. The analysis given will, however, indicate the degree of improvement that can be expected with use of the lateral interface equalization unit.
[0057] To compare the wafer chuck system with and without the equalization some simplifying assumptions will be made:
[0058] 1. Heat flux to the wafer is constant across the pedestal.
[0059] 2. The chuck is transferring heat only to the cooling fluid
[0060] 3. Heat is absorbed by the cooling fluid as if the fluid traveled across a diameter of the pedestal.
[0061] 4. Heat transfer in the chuck body will be considered as one-dimensional: No consideration will be given to complex two and three dimensional models.
[0062] Using these assumptions and making some abbreviated calculations about the conditions that would occur in a chuck without the lateral temperature interface it is found that the temperature difference that exists across the pedestal is essentially the full 10° C. that the cooling fluid undergoes as the fluid traverses the pedestal and absorbs the 2 kw that impinges on the wafer surface. The heat conducted along the chuck in the aluminum body of the chuck is only around 3% of the total 2 kw so that it has little influence on the temperature difference within the cooling fluid's heat exchanger. Thus the chuck surface under the wafer will show the entire 10° C. temperature difference from the point at which the fluid enters the chuck heat exchanger to the point where the fluid leaves. The heat impinging on the wafer will not vary due to this temperature difference but the temperature of the wafer itself certainly will. As the wafer heats in the course of processing the wafer temperature at any point will reflect the temperature of the pedestal adjacent to the wafer at that point plus the temperature difference between wafer and chuck-calculated to be about 13.9° C. per CPT# 1 above.
[0063] The introduction of the lateral temperature equalizing unit into the thermal system introduces a temperature difference comprised of the difference from the chuck surface under the wafer to ammonia boiling in the wick (CPT# 2 , ΔT=5°) plus that of the ammonia condensing on the plugs (CPT# 3 , ΔT=2.5°). This is a total of 7.5° C.; thus the addition of the equalization unit into the system increases the overall ΔT between wafer and cooling fluid. That additional temperature difference introduced is not the full 7.5° calculated. The effect of the interface equalization unit is that of a bar, the thermal conductivity of which is close to infinity in the direction parallel to the interface between wafer and chuck, and finite in the orthogonal direction. The temperature difference introduced by the equalization unit of the above model will be a total of not much more that 2.5° C. This is because the unit integrates the effect of the 10° C. temperature difference in the chuck caused by heating of the cooling fluid. The final temperature difference between any points on the upper surface of the chuck with lateral temperature equalization unit will be of the order of 0.25° C. or less if the heat flux impinging on the wafer surface is constant and the pressure between wafer and chuck is kept constant.
[0064] Although the concepts which provide apparatus and methods in accordance with the invention are particularly advantageous for the difficult problems involved in lateral stabilization of wafer temperatures, they are also useful in other applications. Manufacturing processes which use heated forms or molds to make critical surfaces, for example, may require temperature uniformity across a mold surface area, which can be facilitated when mold designs permit use of gravity for collection of an appropriate fluid. Heated molding processes are increasingly being used for forming complex optical surfaces, such as diffractive elements and aspheric lenses, and in such processes uniform surface temperatures across an area can be critically important. In a number of technologies, temperature stabilization of different elements in a physical array is a requisite for meeting critical operating requirements. In optical systems using wavelength division multiplexing, for example, signals are multiplexed and demultiplexed by glass or birefringent crystal elements mounted on a temperature controlled base, and a temperature equalization system can be of benefit in design as well as operating performance.
[0065] Although a number of forms and variations have been described, the invention is not limited thereto but includes all alternatives and modifications within the scope of the appended claims.
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In many processes used in fabricating semiconductors the wafer is seated on the top surface of a pedestal and heated in a high energy process step, such as plasma etching. The pedestal, chuck or platen may be cooling but the wafer gradually heats until the process can no longer continue. Where large, e.g. 300 mm diameter, wafers are being processed the temperature level across the wafer is difficult to maintain substantially constant. In this system and method the lateral temperature distribution is equalized by a heat sink structure in a chamber immediately under the wafer support on top of the pedestal. A number of spatially distributed wicking posts extend downwardly from a layer of wicking material across the top of the chamber, into a pool of a vaporizable liquid. At hot spots, vaporized liquid is generated and transported to adjacent condensation posts extending up from the liquid. The system thus passively extracts heat to equalize temperatures while recirculating liquid and assuring adequate supply. The free volume above and within the liquid, and the short distances between posts, assure adequate heat transfer rates.
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BACKGROUND OF THE INVENTION
The present invention relates to a spark circuit, particularly--but not exclusively--a spark circuit suitable for ignition purposes for heating equipment used on automobiles.
Spark circuits are used to ignite such combustible fuels as gasoline, diesel oil or gas on heating equiqment; they have arrangements which interrupt the flow of electrical current in the primary winding of the ignition coil which causes a high-voltage pulse to be produced in the seconary and the high voltage in turn produces an ignition spark which jumps across a spark gap defined by electrodes which extend into the combustible medium, respectively into the space or chamber of the heating equipment into which such combustible medium is admitted.
Where this type of equipment is used in e.g. private homes, it is mostly operated with a net-current supplied leakage-reactance transformer. For mobile applications, such as motor vehicles, boats, vans or mobile homes, this type of equipment is used, inter alia, to operate heating equipment. If such heating equipment is not operated by the drive of the vehicle itself (e.g. hot water from the radiator), a spark circuit is necessary which receives electrical energy from the vehicle battery or from the generator driven by the vehicle drive.
It is known to use various mechanical chopper or vibrator arrangements which operate according to the principle of Wagner's Hammer; however, these are subject to malfunction, have a relatively short life time and are rather expensive to manufacture, in addition to which they tend to produce high-frequency interference. For this reason it is now most common to use electronic interrupter circuits which are constructed either as self-controlled freely oscillating converters, or else are constructed as remote controlled astable multivibrators. There are various types and special constructions of these electronic circuit arrangements.
In all of them, however, there is a strong dependence of the starting voltage U Z and the spark energy W f upon the respective battery voltage or other supply voltage U bat . As a result, whenever such equipment is used in the conventional vehicle supply systems having 12 volt or 24 volt batteries, respectively generators, especially adapted construction of the spark circuit is needed. In addition, the strong dependency of the characteristic lines for the starting voltage and the spark energy in dependence upon the battery voltage, has the disadvantageous result that particularly in the reduced-voltage operation which is especially important during winter due to cold and weakened batteries, the reduced current supply causes the starting voltage and even more the spark energy to drop. The relationship is primarily proportional to the battery voltage and starting voltage and quadratic as between battery voltage and spark energy. In extreme cases this can mean that too small a starting-ignition voltage and/or too small a spark energy exist to cause ignition, so that the heating system cannot operate. In addition, the known spark circuits have the further disadvantage--and this is particularly true for the remote-controlled spark circuits--that in the overvoltage region there is a high amount of lost-energy heat due to such erasion effects in the exciter winding.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to avoid the disadvantages of the prior art.
A more particular object of the invention is to produce a spark circuit which is equally well suited for operation with 12-volt and 24-volt current-supply systems.
Still another object of the invention is to provide a spark circuit of the type in question in which the disadvantages are avoided which result from the voltage fluctuations of plus-minus 25% of nominal voltage, which are permissible in motor vehicle supply circuits.
Pursuant to the above objects, and others which will become apparent hereafter, one feature of the invention resides in a spark circuit, which is particularly but not exclusively suitable for heating equipment for automobiles, which comprises a first source of electrical energy; a charging circuit connected with the source and including an ignition coil having a primary and normally conductive electrically operated switch means operative for interrupting current flow in the primary. A second source of constant electrical energy is connected in circuit with the switch means and supplies the same with current required to keep the switch means conductive. Comparator means is connected in circuit with the primary and operative for comparing the actual value of current flowing in the primary against a predetermined nominal value, and for momentarily interrupting the supply of current from the second source to the switch means when the aforementioned values reach parity, so as to render the switch means non-conductive during the interruption with resulting auto-induction in the secondary of the ignition coil.
The invention will hereafter be described with reference to exemplary embodiments illustrated in the drawings. However, it should be understood that these are for purposes of explanation only and that the scope of the protection sought is defined exclusively in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram, showing the qualitative relationship of the starting voltage and the spark-energy dependence upon the operating voltage in the prior-art systems;
FIG. 2 is a block diagram of a spark circuit according to the invention;
FIG. 3 is an actual circuit diagram of a spark circuit according to the invention; and
FIG. 4 is a view similar to FIG. 1, but illustrating the same relationships as in FIG. 1 as applied to a spark circuit according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring firstly to the diagram of FIG. 1 which relates to the prior-art systems, it will be evident that there is a strong dependence of the starting voltage U z and the spark energy W f in dependence upon the operating voltage U bat . One result of this is that for operating voltages voltage ranges U1 and U2 (for example 12 volts and 24 volts) different spark circuit are required. In addition, due to the strong battery voltage dependence each such spark circuit is nevertheless prone to substantial dangers of malfunction, because these spark circuits must be so constructed that even at the permissible supply voltage fluctuations of plus-minus 25% of the nominal current they are still capable of operating satisfactorily.
The invention avoids these problems, as will be discussed hereafter.
FIG. 2 is a block diagram illustrating a spark circuit according to the present invention. When the positive and negative pulse of the spark circuit in FIG. 2 are connected to the corresponding pulse of a non-illustrated battery, current flows via the device 1 which protects against damage due to inadvertent reversal of the pole connections. This current charges the capacitor 2 which serves as a buffer element and a high frequency filter. Parallel thereto the current flows through a shunt 3, the primary winding of the ignition coil 4 and the semiconductor switch 5 which is in conductive state, back to the current source, i.e. here the battery.
Due to the inductivity of the primary the current value will be zero at the moment the circuit is energized, and will then rise according to an exponential function. This produces a proportional voltage drop at the shunt 3, and this voltage drop is compared in the current comparator 6 with a predetermined current value. When the two values reach parity, i.e. as soon as the voltage drop begins to exceed the predetermined nominal value, a trigger signal is initiated which energizes the impulse circuit 7--preferably in form of a monostable flip-flop--to produce a single pulse of a pre-defined length. For the duration of this impulse the constant current source 8, which produces the control current necessary to maintain the semiconductor 5 conductive, is deactivated. As a result, the current flow through the primary of the ignition coil 4 is abruptly interrupted, causing the auto-induction in the secondary of the ignition coil 4, and thus producing the high-voltage pulse necessary to produce the ignition spark at the not illustrated spark electrodes.
After expiration of the time for the impulse produced in the circuit 7, the constant current source 8 is re-activated and the current supplied by it to the semiconductor switch 5 renders the latter conductive again so that the flow of current through the primary circuit of the ignition coil 4 can begin again.
The stabilizing circuit 9 produces the necessary constant starting voltage which is acquired for supplying the circuit 7 and the current comparator 6, as well as to produce the nominal value for the current comparator 6. As mentioned before, the supply voltage acting at the positive and negative pulse of the spark circuit may fluctuate by plus-minus 25% in accordance with the permissible fluctuations of the vehicle current supply, so that the stabilizing circuit 9 is necessary in order to obtain the required constant starting voltage.
Because of the physical relationship for the energy storage in an inductance W 1 =1/2×L×L 2 the stored energy and thus the spark energy and the starting voltage can be maintained constant with the received current--i.e. the current which was flowing immediately before the interruption of the current flow through the primary of the ignition coil 4--is supervised and maintained constant since the inductance itself already constitutes an ignition coil constant.
The use of a constant current source in place of the usually employed resistance between the trigger circuit and the semiconductor switch, makes it possible to maintain the control conditions for the semiconductor optimum and independent of the battery voltage. If a resistor were used, the control current for the semiconductor switch 5 would be low if the battery current were low, which would lead to an additional voltage loss at the semiconductor switch 5. On the other hand, if the operating voltage would be high, a strong heating-up of the resistor would result unless special expensive counter measures were used.
The diagram in FIG. 4 illustrates the same relationships as the one in FIG. 1, but as they apply to the spark circuit according to the present invention. It will be seen that the two values (i.e. starting voltage and spark energy) now show a behavior which is largely independent of operating voltage over a wide voltage range, so that it is possible in particular to so construct the inventive spark circuit that it is equally well suitable for 12 volt as well as for 24 volt operating-current supply systems.
It will be appreciated that the invention is by no means restricted to the exemplary embodiment, since various modifications are possible without departing from the principle of the invention. Moreover, the spark circuit according to the invention is not usable only as an ignition spark circuit, but is suitable generally in the area of stabilized high-voltage production.
The invention having been described hereinbefore with reference to an exemplary embodiment, it will be understood that the scope of protection which is sought is defined exclusively in the appended claims.
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A spark circuit for heating equipment used on automobiles in which a switch interrupts current flow in the primary of an ignition coil. A comparator compares the actual value of current flowing in the primary against a predetermined nominal value, and current to the switch is interrupted when the values reach parity, so as to render the switch non-conductive during the interruption with resulting auto-induction in the secondary of the ignition coil.
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AREA OF THE INVENTION
The present invention relates to a process for combusting black liquor in recovery boilers. The invention also includes a recovery boiler for implementing the process according to the invention.
STATE OF THE ART AND PROBLEMS
Recovery boilers for combusting black liquor which is obtained during cellulose cooking have been well known for many decades. Their task is, on the one hand, to generate energy by means of the combustion and, on the other hand, to recover chemicals which were used during the cellulose cooking and which are released in the smelt state during the combustion and tapped off from the bottom part of the recovery boiler. Recovery boilers are large installations and, apart from generating a large quantity of energy and recovered chemicals, also generate a large quantity of flue gases. These flue gases contain, inter alia, nitrogen oxides which have arisen during the combustion of the liquor.
During recent years, ever stricter requirements have been introduced with regard to the discharge of nitrogen oxides into the atmosphere. It is well known that these oxides contribute to acidification and other unfavourable effects on the natural environment. Nevertheless, the quantity of nitrogen oxides which is emitted from the recovery boilers of the wood-processing industry is low as compared with that originating from cars, etc. While the contents are normally within the range of 40-70 mg of NO 2 /MJ (calculated as the effective heat value in a reducing medium), even these low contents have to be decreased substantially in future. The discharges have been shown to depend principally on the nitrogen content of the fuel, i.e. the black liquor, and this content will increase in the future as the chemical cycles are closed ever more stringently. This will result in the nitrogen oxide emissions increasing if countermeasures are not taken.
Factors which can effect the formation of nitrogen oxides are dwell time, temperature and oxygen content.
As a result of experience gained from conventional power boilers based on coal, oil and gas, it is known that substoichiometric conditions with regard to the oxygen supplied to the combustion zone, in combination with a final combustion, for the purpose of obtaining maximum energy evolution, in a so-called overfire air register which is placed directly above (or after) the combustion zone, result in a lower No x emission.
This technique has also, for a long time now, been used for other reasons in recovery boilers, where primary air and secondary air have been supplied below (before) the black liquor, and tertiary air has been supplied immediately above (after), in a similar manner to that in which overfire air has been used for power boilers. This is described in more detail by Anderson & Jackson in the TAPPI Journal for January 1991, pp. 115-118.
SE 468 171 discloses a method for decreasing the content of nitrogen oxides in the flue gas, in which method a part of the combustion air is supplied, as a final portion, at a very high level so that a higher grade of reducing atmosphere is maintained, without any extra addition of reducing substances, over a distance of 10-20 metres or greater, from the region of the liquor injection and up to the point of the final addition of air, corresponding to a dwell time under normal loading of 2.5-5 seconds or more. This method presupposes that the recovery boiler is relatively tall so that the reducing atmosphere can be maintained for a sufficiently long time.
Another method has been proposed for reducing the NO x in the recovery boiler, which method uses the technique, which has been developed for power boilers, involving thermal or selective non-catalytic reduction (SNCR), by means of supplying a reducing substance, in the form of natural gas, ammonia or urea, relatively high up the recovery boiler for the purpose of reducing nitrogen oxides which have been formed. When natural gas is used, large quantities of uncombusted residual products are formed which have to be finally combusted by means of a further addition of air. When urea or ammonia is used, they are normally added, in the form of an aqueous solution, to the upper parts of the furnace space. A major disadvantage of using this method in a recovery boiler is that an aqueous solution is being supplied, involving the risk of causing water/smelt explosions. This can occur, for example, in association with faulty handling and if corrosion damage arises which is caused by the urea solution.
An alternative to introducing an aqueous solution of ammonia can be to introduce it after volatilization using spray guns. This procedure requires many spray guns and the handling of concentrated ammonia in the immediate vicinity of the boiler. In addition, there is the risk of obtaining very high concentrations of ammonia locally in the furnace, and consequently non-optimal conditions for NO x reduction.
SE 460 221 discloses a method of supplying ammonia gas to an MBC (Multiple Bed Combustion) boiler, in which method the ammonia gas is supplied to secondary and/or tertiary air, which is mixed with flue gas and supplied to one or more upper fluidized beds for the purpose of fluidizing these beds. While this technique can function well in an MBC boiler, it does not do so in a recovery boiler since the temperature distribution is much better in an MBC boiler.
SOLUTION AND ADVANTAGES
However, the present invention has resulted in a process for obtaining, in association with the combustion of black liquor in recovery boilers, flue gases having a low content of nitrogen oxides, n which process a part of the combustion air is supplied, as a final portion, at a high level so that a reducing atmosphere is maintained, from the region of the liquor injection and up to the final addition of air, over a distance of 10-20 metres or more, corresponding to a mean dwell time under normal loading of 2.5-5 seconds or more. The method is characterized in that ammonia is supplied to the said final portion of combustion air in a quantity corresponding to 100-400% of the stoichiometric requirement for complete reduction of nitrogen oxides present in the flue gas. If the boiler is not equipped with a flue gas wash, the ammonia is preferably supplied in a quantity corresponding to 100-200%. If the boiler is equipped with a flue gas wash, the ammonia is preferably supplied in a quantity corresponding to 100-300%.
The ammonia is added to the combustion air either in conjunction with the latter being introduced, or even more preferably before the latter is introduced, into the furnace space. The ammonia is preferably added in gasified form, with the gasification taking place either by means of volatilization of pure, liquid ammonia or by means of evaporating ammonia from its aqueous solution.
It is simplest to add the ammonia directly to the combustion air either immediately upstream or immediately downstream of the air fan. Alternatively, ammonia gas can be supplied directly to the air ports (supply openings) by way of separate compressed air-driven feed lines.
The final portion of the combustion air, which portion contains ammonia according to the invention, can be supplied in two stages at two high levels.
The quantity of ammonia-containing combustion air which, according to the invention, is to be added at the high level(s) constitutes approximately 2.5-50%, preferably 5-15%, of the total combustion air.
The process according to the invention also includes the proportion of nitrogen oxides in the flue gases being monitored with the aid of a control system which automatically regulates the supply of air to the different levels and the supply of ammonia to the combustion air. The quantity of ammonia which is to be supplied, i.e. 100-400% of the stoichiometric requirement for complete reduction of nitrogen oxides present in the flue gas, preferably 100-200% for boilers without a flue gas wash and 100-300% for boilers with a flue gas wash, is determined by measuring the content of nitrogen oxide and ammonia in departing flue gases. The stoichiometric requirement which is meant in this patent application is set in the conventional manner at 1 mol of NH 3 per mole of NO x . The quantity of ammonia which is added then becomes 1-4 mol per mole of nitrogen oxide, preferably 1-2 mol per mole for boilers without a flue gas wash and 1-3 mol per mole for boilers with a flue gas wash.
The requisite quantity of ammonia can be obtained either by buying it or else generating it internally in the mill for example by stripping condensates.
When the nitrogen oxides are reduced, it is assumed that nitrogen and water are formed in accordance with the following overall reaction:
NO+NH.sub.3 +OH→N.sub.2 +2H.sub.2 O
The aim is that all the ammonia should be oxidized to nitrogen. Any possible discharge of ammonia in the flue gases is minimized by measuring and adjusting the quantity added. In the case of boilers which are equipped with a flue gas wash, a larger quantity of ammonia can be added without there having to be any increase in the discharge of ammonia. This is advantageous since a high level of ammonia addition results in a greater reduction of the nitrogen oxides.
The invention also includes a recovery boiler for combusting black liquor in accordance with the described method. The recovery boiler is characterized in that, in addition to conventional devices for supplying primary air, secondary air and tertiary air, and devices for supplying high tertiary air or quaternary air at a substantially higher level, in accordance with SE 468 171, it also includes devices for supplying ammonia to the said high tertiary air or quaternary air. In this context, high tertiary air is understood to mean air which has been branched off from the normal tertiary air line, while quaternary air is understood to mean air which comes from a separate line.
In the recovery boiler according to the invention, the devices for supplying ammonia-containing high tertiary air or quaternary air can be situated at one or more levels around 10-20 metres above the level at which the liquor is injected.
The recovery boiler according to the invention can be provided with two or more rows of supply openings, on either side of the furnace space, for supplying ammonia-containing high tertiary air or quaternary air, with it being possible for one level to be at approximately 10 metres and the other at approximately 16 metres above the level at which the liquor is injected.
According to the invention, it is expedient for the uppermost air supply openings, for the ammonia-containing air, to be located directly below, preferably 1-4 metres below, and even more preferably 2-3 metres below, the region where the boiler is narrowest, i.e. where the internal "nose" is arranged.
Finally the recovery boiler according to the invention is characterized in that it includes a control system for automatically controlling the different supply streams of the combustion air and also a control system for the ammonia supply.
Consequently, a major advantage of the invention is that, since the ammonia is supplied in gaseous form, there is no risk of water/smelt explosions.
A further advantage is that the ammonia is introduced into the boiler where it does the most good, i.e. when almost all the combustion reactions have finished and the temperature has fallen to approximately 950° C.
Yet another advantage is that only small quantities of concentrated ammonia have to be handled in the immediate vicinity of the boiler since this ammonia is rapidly diluted in the high tertiary air or quaternary air. In addition, the turbulence which the jets of high tertiary air or quaternary air create in the boiler distribute the ammonia very efficiently in the boiler, with optimum concentration conditions being created for reducing nitrogen oxides.
In that which follows, the invention will be described in more detail with reference to the attached drawing, which schematically shows a recovery boiler according to the invention in cross section, and a diagram which shows the effect which is achieved by the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a recovery boiler for making use of the invention.
FIG. 2 shows a comparative diagram of the nitrogen oxide content in the flue gases when supplying air/ammonia.
FIG. 3 shows two alternative embodiments for adding ammonia to the air.
DETAILED DESCRIPTION OF THE INVENTION
The recovery boiler as shown in FIG. 1, which is of a conventional type for a steam production of approx. 250 t/h, Includes liquor sprayers 1 which are situated in the lower part of the recovery boiler.
Openings 2 for blowing in secondary air are located below these liquor sprayers 1. Start burners, which are fed with oil or gas, are also present at this level. Openings 3 for supplying primary air are present below the level for supplying the secondary air. Openings 4 for blowing in tertiary air are located above the liquor sprayers 1. Additional air supply openings 8 are present, on both sides of the furnace space, at a high level in the boiler directly below the region where a tapering of the boiler, the so-called "nose" 5, is located. While there can be several of these openings, expediently eight on both sides, the actual number is not critical. In accordance with SE 468 171, a part of the tertiary air, which would normally be supplied lower down at position 4 in the boiler, is supplied through these air openings. The quantity which is normally introduced at position 4 is thus decreased, and this quantity is allowed to flow in at the most highly situated air supply devices 8. Expediently, the quantity of air which is supplied at this upper position amounts to a quantity corresponding to 5-15% of the total air intake. In accordance with the invention, ammonia gas is supplied to this quantity of air before the latter is introduced at position 8. This means that a gas atmosphere, which is entirely or partially reducing depending on the content of ammonia, carbon monoxide and smaller quantities of hydrogen and hydrogen sulphide, is present in the region from position 4 to position 8. Otherwise, the boiler includes conventional devices, such as a heat exchanger 6 and, under the boiler, a collecting vessel 7, termed dissolver tank, for smelt, which consists of recovered chemicals in the form of known sodium salts.
At position 8, and immediately thereafter, the reducing gases are combusted to nitrogen, carbon dioxide, water, etc. and release the last quantity of energy which is possible. This combustion takes place at a temperature of the order of 900-1100° C., at which temperature only very small quantities of nitrogen oxides are formed. These measures result in the quantity of nitrogen oxides being markedly decreased. This is shown in the attached diagram (FIG. 2). The diagram makes clear, on the one hand, the improved result which is achieved with the invention as compared with only adding quaternary air (i.e. without ammonia in accordance with SE 468 171) and, on the other hand, that the effect achieved improves as the amount of ammonia added becomes more overstoichiometric. As has previously been mentioned, any departing excess of ammonia can advantageously be washed away in a flue gas wash.
FIG. 1 also shows a further row of air intakes for overfire air at position 9. While these air intakes can be dispensed with, they can also complement the air intakes at position 8. The number of air intakes at position 9 can be the same as at position 8, expediently eight intakes on both sides of the furnace.
FIG. 3 shows two alternative methods of adding the ammonia to the air. Part no. 10 symbolizes the ammonia source. Metering is effected using a device 11, after which the ammonia is volatilized, 12, and the flow is measured, 13. According to alternative 1, the ammonia is supplied to each air box 16 (for the supply openings 8, 9) through separate compressed air-driven, 18, feed lines 14, 15. Each such feed line can be regulated separately. According to alternative 2, the ammonia is instead supplied to the air immediately downstream of the air fan 17, before the air line divides for supply to the different air boxes 16.
As has been said above, the essential point with regard to the invention is that ammonia is added to the last part of the air which is supplied at a high level in the recovery boiler. In addition, the quantity of air at lower levels is decreased to such a degree that an environment which is reducing, or almost reducing, is obtained for a very long time, approximately 2.5-5 seconds, in the normal recovery boiler. This time is to be compared with that which is obtained, namely approximately 0.6 seconds, when the last part of the air is added at the tertiary position 4, approximately 3 metres above the liquor sprayers. Besides resulting in a more reducing atmosphere below the level of the uppermost air addition, decreasing the addition of tertiary air at the same time as making an addition of quaternary air also results, as compared with conventional operating conditions, In a lower temperature below this level and a temperature above the level which is higher relatively. The distribution of air between the tertiary level and the quaternary level can thus be used as a method for guiding the temperature above the site of quaternary air addition to a level which is optimal for reducing nitrogen oxides. This temperature depends, to a high degree, on the content of reducing substances, such as hydrogen, in the flue gases. For example, Lyon ("Thermal DeNO x ", Env. Sci. Tech. Vol. 21, No. 3, 1987) has demonstrated that the optimum temperature decreases from 950° C. to 700° C. when the H 2 /NH 3 , ratio increases from 0 to 1.3.
Consequently, by means of arranging the overfire air intake so high up the boiler and at that point admitting a part of the air which would otherwise have been admitted at the tertiary air intake, and in this way obtaining a lower content of nitrogen oxides, the opportunity has been obtained to regulate the content of nitrogen oxides in the exhaust gases by means of adding ammonia to the overfire air and varying the air streams. According to the invention, this can be done automatically by measuring the content of nitrogen oxide and ammonia in the flue gases and allowing these measured values, for example via a computer, to control both valves for blowing the Quantities of air into the primary, secondary, tertiary and high tertiary or quaternary air intakes and also the quantity of ammonia gas which is added to the high tertiary or quaternary air intakes. In this way, it is possible to compensate for variations in the quality of the fuel, etc and consistently obtain a minimal quantity of nitrogen oxides in the flue gases without jeopardizing other operational parameters or occasioning an unacceptably high content of ammonia in the flue gas.
The invention has been described in conjunction with a modern recovery boiler for a steam production of approximately 250 t/h and having a normal height of approximately 50 metres, with the uppermost air intake, for ammonia-containing air, expediently being placed at approximately 16 metres above the liquor sprayers. The same ratio between height and distance above the liquor sprayers can also be used in the case of larger boilers. However, in the case of shorter boilers, another ratio may be expedient since, in the case of such boilers, the dwell time may in any case be too short for satisfactory reduction of the nitrogen oxides.
The invention is not limited to the exemplary embodiment shown and can be varied in different ways within the scope of the patent claims. Other reducing agents, for example urea, can naturally be used in addition to, or instead of, ammonia.
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The invention relates to a process for combusting black liquor in recovery boilers where the intention is to obtain flue gases which have a low content of nitrogen oxides (NO x ). The invention is characterized in that ammonia is supplied to a part of the combustion air, which part is then supplied to the recovery boiler, as the final portion, at a high level, so that a reducing atmosphere is created in a very large part of the recovery boiler and for a long time, of at least 2.5-5 seconds or more. The invention also includes a recovery boiler for implementing the above mentioned process.
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PRIORITY CLAIM
The application claims the benefit of priority under 35 U.S.C. §119(a) from Great Britain Application No. 0329261.2, entitled, “Device Control Support Information Acquisition,” filed on Dec. 18, 2003, which disclosure is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the automated extraction, aggregation and analysis of support information for networked devices, and particularly but not exclusively for mass-produced hard disk drive controller devices attached to storage area networks having storage virtualization appliances.
2. Description of the Related Art
In the field of this invention it is known that in today's heterogeneous Storage Area Network (SAN) environment users can connect almost any Fibre-Channel controller device to their SAN and use the storage it is providing. With the advent of virtualization devices, especially symmetric virtualization devices, this storage can be handled in device-agnostic ways using the virtualizer as the central point of control in a SAN.
However, not all devices are supported by every SAN virtualizer and, moreover, every controller device may act in subtly different ways from other controllers in the system. The virtualizer therefore in theory can support any controller device that is presenting storage, but can only use the supported devices and only the commonly-implemented protocols. Any specific controller device may not be configured or optimally configured for use by, or be optimally used by, the virtualizer.
As an example, consider that many different implementations of the Small Computer Serial Interface (SCSI) exist in different devices. Each device supports a slightly different subset of the totality of the SCSI commands that are available in the SCSI command interface. When such devices are in communication with standard hardware and software, it is necessary to limit communication to the intersection of each participant's supported subset of commands. This in turn limits the functionality that is available to the system as a whole, and this is clearly undesirable.
Today there is no easy way to determine exactly what storage controllers a customer is attaching to a virtualizer without market research or other humanly-performed techniques. This being the case, there is no fast, simple way of determining that there is a greater requirement among customers for support of one type of device or additional command subset than there is for support of another device or additional command subset. There is likewise no fast and simple way, in a service call situation, of determining whether the problem has been caused by an attempt to use an unsupported device or an unsupported (or not yet supported) subset of the supported device controls. A need therefore exists for an improved system and method for device control support analysis wherein the above mentioned disadvantages may be alleviated.
SUMMARY OF THE INVENTION
The present invention comprises a method, program and system for acquiring analyzed device control support information in a field population of distributed devices operable to be connected in a network to a virtualizer, comprising: an aggregator adapted to be coupled to said virtualizer; said virtualizer adapted to be coupled to at least one device in said field population and operable to query device control support data from the device and forward said device control support data to said aggregator; and said aggregator being operable to aggregate device control support data and forward aggregated data; wherein a host is arranged to receive said aggregated data across the network and to analyze the aggregated data to provide analyzed device control support information for the field population of distributed devices.
All objects, features, and advantages of the present invention will become apparent in the following detailed written description.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is described in a preferred embodiment in the following description with reference to the drawings, in which like numbers represent the same or similar elements, as follows:
FIG. 1 shows a preferred embodiment of a system in accordance with the invention;
FIG. 2 shows a flow chart of a preferred method of operation of the embodiment of FIG. 1 .
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 , there is shown a system 1000 comprising a data collector/analyzer host 102 , utilized by a virtualizer vendor in a manner to be further described below, coupled to a Wide Area Network (W2N) 104 , which may be, or may comprise, the Internet. The coupling is by means of a communications component 202 .
A number of disk drive controllers 110 , 110 ′, 120 , 130 (manufactured by one or more disk drive controller manufacturers and marketed by one or more vendors, who may themselves be manufacturers also) are operated by a customer, and used to control magnetic disk storage for typical disk drive applications, such as databases, file servers, data storage, paging storage and the like.
The disk drive controllers 110 , 110 ′, 120 , 130 are mass-produced by the one or more manufacturers, and may be substantially identical to each other, may be variants of a particular family of disk drive controller designs, or may differ in many ways from one another. For example they may support many different configurations of storage and many different subsets of the typical device control commands or APIs. It is envisaged that the manufacturers may produce and the vendors sell many thousands of disk drives and respective controllers of the various families.
The disk drive controllers 110 , 110 ′, 120 , 130 are attached to a Storage Area Network (SAN) Fabric 140 comprising a virtualizer 100 which in turn is coupled to a SAN management host 190 . In an example, disk drive controllers 110 , 110 ′ are fully supported, while disk drive controller 120 only supports a restricted subset of device control commands which does not yet meet the supported configuration standard, and disk drive controller 130 is as yet not supported for use in this SAN fabric.
Virtualizer 100 queries the disk drive controllers 110 , 110 ′, 120 , 130 over the Fibre Channel Fabric to determine their model numbers, their version numbers and their vendors, using commands that are typically supplied as part of a supported command set, such as are commonly published as industry standards. This may be, for example, direct SCSI protocols or, in one alternative, SCSI Enclosure Services (SES) commands.
After scanning the attached Fibre Channel Fabric 140 , the data from each of the disk drive controllers 110 , 110 ′, 120 , 130 is passed to the customer's SAN management host 190 , where it is collated or aggregated by aggregator 200 for submission to the vendor of the virtualizer. It is envisaged that, in a most preferred embodiment, this transmission would be by means of an Internet transmission, using, for example HTTP or HTTPS as the protocol. Such protocols advantageously allow the data to pass through intervening firewalls without causing security breaches. If required (and if the customer were to permit it) customer details could also be passed with the data. It would, of course, be necessary to ensure the security of any such sensitive data while in transit, and so some form of encryption or obfuscation may be called for.
Communications component thus sends the aggregated and possibly encrypted and/or compressed information via WAN 104 to a corresponding communications component 204 at vendor's system 1000 , which in turn passes the information to the data collector/analyzer host 102 . In a preferred embodiment this device support information is temporarily stored in a local database storage 206 on the customer SAN management host 190 , and periodically uploaded to the data collector/analyzer host 102 via the WAN 104 .
It will be appreciated that the data can be directly uploaded to the data collector/analyzer host 102 as it becomes available. However the use of database storage 206 helps to address the scaling issue as the data collector/analyzer host 102 may be servicing field populations numbering many thousands or millions of individual devices.
A special case may be made for the service call situation, in which a vendor may request that information be sent over the network to indicate the current state of all the disk drive controllers 110 , 110 ′, 120 , 130 attached to a customer's virtualizer, to determine whether the customer's problem has been caused by attachment of an unsupported disk drive controller 130 or the possible use of an unsupported subset of the device controls by disk drive controller 120 . Referring now also to FIG. 2 , there is shown an illustrative flow diagram of the operation of a preferred embodiment of the present invention.
At step 300 , the process starts, and at step 302 , the virtualizer queries the disk drive controller devices for their device characteristics. At step 304 , the virtualizer forwards the data to the SAN host, which aggregates it at step 306 and transmits it to the vendor's data collector/analyzer host at step 310 . An optional step of storing the data locally may be performed at step 308 , in which case transmitting step 310 may be postponed until some suitable later time.
Transmission step 310 continues until completion is received from the vendor's data collector/analyzer host at test 312 . On receiving completion from the vendor's data collector/analyzer host at test 312 , the SAN host's part of the process is finished. At step 314 , the vendor's data collector/analyzer host analyzes the data and then tests at tests 316 , 320 and responds to the output in different ways at steps 318 , 322 , 324 .
Responsive to determining at test 316 that the device is supported and optimally configured, step 318 may store the data separately for reference purposes. In an alternative, the data may be discarded, if there is no further use for it.
Responsive to determining at test 316 that the device is either not supported or not optimally configured, test 320 is performed to determine if this data relates to a service call. If so, the data is used at step 322 to respond to the service call.
Responsive to determining at test 320 that this data does not relate to a service call, the data is used at step 324 as input to the vendor's development and test plans to modify the relative priorities of various future device control support requirements. This iteration of the process completes at terminator 326 .
Thus, when the device support information reaches the host it is processed and the aggregated results may be used to determine, for example, whether there is a need for a prioritized development effort to support a popular, but presently unsupported device. In an alternative, the aggregated results may be used to determine whether a particular subset of device controls, for example, SCSI commands, needs to be accommodated in the virtualization device, in the attached hosts or in the device controllers. It will be understood that the device, system and method for automatically acquiring and aggregating device control support information described above provides the following advantages:
Recovered information is provided from a large population of drives in the field population, and may be used to perform detailed analysis with greater predictability and less tolerance than present arrangements. Trends may also be detected.
The analysis can advantageously determine if the controllers attached are indeed supported (if for example the customer has put in a service call to the vendor) and validate that a specific controller is not causing the problem, determine the numbers of unsupported controllers in the field-giving advantageous market data relating to the need for the support of hitherto unsupported devices, and, if some threshold has been set, and this is attained for a certain controller type or for a set of supporting commands and responses, the vendor's development and test organizations can be primed to validate the attachment of the specific controller and hence provide improved support particularly to the customer who has installed a heterogeneous group of devices.
It will be appreciated by a person skilled in the art that alternative embodiments to those described above are possible. For example the above invention is applicable to a wide range of mass produced devices which currently are or may be in the future connected to a network including computer tape drives, printers, and the like.
Furthermore it will be understood that the means of exchanging data between the disk drive controllers 110 , 110 ′, 120 and 130 and the data collector/analyzer host 102 may differ from that described above. For example for a disk drive controller or virtualizer not coupled to the Internet, removable storage media may be used for the exchange of data.
It will be appreciated by one of ordinary skill in the art that the method described above will typically be carried out in software running on one or more processors (not shown), and that the software may be provided as a computer program element carried on any suitable data carrier (also not shown) such as a magnetic or optical computer disc. The channels for the transmission of data likewise may include storage media of all descriptions as well as signal carrying media, such as wired or wireless signal media.
The present invention may suitably be embodied as a computer program product for use with a computer system. Such an implementation may comprise a series of computer readable instructions either fixed on a tangible medium, such as a computer readable medium, for example, diskette, CD-ROM, ROM, or hard disk, or transmittable to a computer system, via a modem or other interface device, over either a tangible medium, including but not limited to optical or analog communications lines, or intangibly using wireless techniques, including but not limited to microwave, infrared or other transmission techniques. The series of computer readable instructions embodies all or part of the functionality previously described herein.
Those skilled in the art will appreciate that such computer readable instructions can be written in a number of programming languages for use with many computer architectures or operating systems. Further, such instructions may be stored using any memory technology, present or future, including but not limited to, semiconductor, magnetic, or optical, or transmitted using any communications technology, present or future, including but not limited to optical, infrared, or microwave. It is contemplated that such a computer program product may be distributed as a removable medium with accompanying printed or electronic documentation, for example, shrink-wrapped software, pre-loaded with a computer system, for example, on a system RON or fixed disk, or distributed from a server or electronic bulletin board over a network, for example, the Internet or World Wide Web. It will be appreciated that various modifications to the embodiment described above will be apparent to a person of ordinary skill in the art.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. For example, the present invention may be implemented using any combination of computer programming software, firmware or hardware. As a preparatory step to practicing the invention or constructing an apparatus according to the invention, the computer programming code (whether software or firmware) according to the invention will typically be stored in one or more machine readable storage mediums such as fixed (hard) drives, diskettes, optical disks, magnetic tape, semiconductor memories such as ROMs, PROMs, etc., thereby making an article of manufacture in accordance with the invention. The article of manufacture containing the computer programming code is used by either executing the code directly from the storage device, by copying the code from the storage device into another storage device such as a hard disk, RAM, etc., or by transmitting the code for remote execution. The method form of the invention may be practiced by combining one or more machine-readable storage devices containing the code according to the present invention with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing the invention could be one or more computers and storage systems containing or having network access to computer program(s) coded in accordance with the invention. While this invention is described in terms of the best mode for achieving this invention's objectives, it will be appreciated by those skilled in the art that variations may be accomplished in view of these teachings without deviating from the spirit or scope of the present invention.
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A system, method and computer program for acquiring analyzed device control support information in a field population of distributed devices operable to be connected in a network to a virtualizer has an aggregator adapted to be coupled to said virtualizer. The virtualizer is adapted to be coupled to at least one device in the field population and operable to query device control support data from the device and forward the device control support data to the aggregator; and the aggregator is operable to aggregate device control support data and forward aggregated data. A host is arranged to receive the aggregated data across the network and to analyze the aggregated data to provide analyzed device control support information for the field population of distributed devices.
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[0001] This application claims the benefit of the Korean Application No. P2003-064442 filed on Sep. 17, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a digital cable broadcast receiver, and more particularly, to a digital cable broadcast receiver and a method for processing a caption thereof that can process a caption of a various types and standards for use in a digital cable broadcast, in an adaptive manner.
[0004] 2. Discussion of the Related Art
[0005] A ground wave broadcast standard for an analog broadcast in USA (United States of America) is an NTSC (national television system committee) standard. The NTSC standard is characterized in transmitting a closed caption such as English, Spanish, using a 21 st line of a VBI (vertical blanking interval) of a broadcast signal. A standard related to the transmission of the closed caption is an EIA (electronic industry association) standard 608. Services provided through a 21 st line of the VBI under the EIA 608 standard are as follows: CC1 (primary synchronous caption service), CC2 (special asynchronous caption service), CC3 (secondary synchronous caption service), CC4 (special asynchronous caption service), Text1 (first letter information service), Text2 (second letter information service), Text3 (third letter information service), Text4 (fourth letter information service).
[0006] In USA, a user has to select, in person, one among the above-mentioned services. Further, since there is no information as to which service is provided among the above-mentioned eight services while a broadcast program is displayed, there has been a difficulty that a user should check, case by case, the services so as to check a service under execution.
[0007] A ground wave broadcast standard for a digital broadcast in USA is an ATSC (advanced television system committee) standard. Further, an EIA 708, which is a standard on a digital TV closed caption (DTVCC), is established. The DTVCC will be described with reference to the accompanying drawings. FIG. 1 illustrates the general bit stream provided to a digital TV. As shown in FIG. 1 , the bit stream includes: audio data, video data, control data (i.e., supplementary information). Data that corresponds to the DTVCC is included in user_data bits of the video data and transmitted under an MPEG-2 (Moving Picture Experts Group-2) video standard and the ATSC standard (A53). At this point, according to the above standards, the DTVCC data can be transmitted up to as much as 128 bytes at its maximum for each user_data region and the total transmission amount cannot exceed 9600 bps (bit per second). Compared with an analog closed caption based on the EIA 608, where the total transmission amount cannot exceed 960 bps, the DTVCC based on the EIA 708 has realized ten times greater bandwidth in its data transmission. The DTVCC based on the EIA 708 can provide sixty-three caption services in total with consideration of the extended bandwidth. In case of the sixty-three digital caption services, there is a difficulty that a user should change settings to find out a desired caption service as was done in the above-described analog closed caption. Due to such reason, in case of providing a DTVCC according to the ATSC standard, a broadcast station must include information called a caption_service_descriptor within an EIT (event information table) or a PMT (program map table) in a PSIP (program and system information protocol). The EIT and the caption_service_descriptor allow a DTV receiver to know what kind of the DTVCC is included in a relevant program.
[0008] The cable broadcast is a little different from the ground wave broadcast depending on regions, or service companies, or broadcast equipments. In particular, the cable broadcast is the same as the ground wave analog broadcast in that transmission is performed on the basis of a letter value and a command set prescribed by the EIA 608 in operating a closed caption. However, the cable broadcast is different from the ground wave broadcast in transmitting the closed caption using other interval of the VBI except a 21 st line of the VBI. That is, some broadcast station transmits a caption using a sixth line of the VBI while other broadcast station transmits a caption using a tenth line. In the meantime, as an analog cable broadcast is switched into a digital cable broadcast, a closed caption standard regarding the digital broadcast has been established independently. The basic object of standards tilted SCTE (society of cable television engineers) 20 and DVS (digital video surveillance) 157 is to convert an analog closed caption for use in the analog cable broadcast into user_data within a video data region for use in a digital TV. Those standards do not include content regarding a DTVCC of the EIA 708 standard but only prescribe content regarding the analog closed caption as is done in the existing standards.
[0009] The ATSC standard regarding the DTVCC does not consider the closed caption under the SCTE 20 or the DVS 157 which are caption transmission standards for use in the cable broadcast. Since a cable broadcast service company has provided a cable set top box appropriate for the company's broadcast to each user, there was little problem in a digital-cable-broadcast generation before an open-cable generation. However, under a new digital broadcast environment such as an open cable and a Cable Ready, there occur problems regarding the standards. That is, under the open cable and the Cable Ready environments whose object is to connect an apparatus generally available in the market, not a specific cable broadcast receiver provided by a specific cable broadcast company, to a cable, a method for transmitting/receiving a caption emerges as a very complicated problem.
[0010] An open cable broadcast signal under regulations of a FCC (federal communications commission) must include a DTVCC and an analog CC (closed caption) prescribed by the EIA 708. Further, the open cable broadcast signal should include user_data of other type prescribed by the SCTE 20 or the DVS 157 and may include a relevant caption at a S-Video, a Composite, a 480i, and a VBI line of the Component output. Therefore, the cable broadcast receiver should know what kind of caption data is included in a digital cable broadcast being received. However, it is difficult for the cable broadcast receiver to judge a kind of caption data being received in view of characteristics of caption data. Accordingly, a user should check in person the caption data through a key or a menu on a remote control. Also, a user should experimentally select and check what kind of caption data is decoded.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention is directed to a digital cable broadcast receiver and a method for processing a caption thereof that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0012] An object of the present invention is to provide a digital cable broadcast receiver and a method for processing a caption thereof that can automatically process caption data of various standards and types.
[0013] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0014] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided a digital cable broadcast receiver including: a demultiplexer for dividing a received broadcast stream into video data, audio data, supplementary information; a controller for judging whether caption data included in the video data is digital caption data or analog caption data on the basis of caption information included in the supplementary information, and outputting a control signal according to a result of the judgment; a digital caption decoder for extracting and decoding digital caption data from the video data according to the control signal; and an analog caption decoder for extracting and decoding analog caption data from the video data according to the control signal.
[0015] The controller judges a number of caption services, a national language, a difficulty level of a caption, a line number and a field of a VBI that corresponds to the caption data, a picture ratio, provided by the caption data included in the video data, on the basis of the caption information.
[0016] If the caption data included in the video data is digital caption data, the controller detects a caption service number that corresponds to the caption data from the caption information and transmits the control signal including the detected caption service number to the digital caption decoder.
[0017] If the caption data included in the video data is analog caption data, the controller judges the caption data's standard on the basis of the caption information. If the caption data is an analog caption data of an EIA 708, the controller detects field information that corresponds to the caption data from the caption information, and transmits the control signal including the detected field information to the analog caption decoder, and if the caption data is an analog caption data of the SCTE 20 or the DVS 157 standards, the controller detects field information and VBI line information that correspond to the caption data and transmits the control signal including the detected field information and the VBI line information, to the analog caption decoder.
[0018] In another aspect of the present invention, a digital broadcast receiver further includes: a program map table (PMT) buffer for storing a PMT included in the supplementary information and transmitting the stored PMT to the controller; an event information table (EIT) buffer for storing an EIT included in the supplementary information and transmitting the stored LIT to the controller; and a graphic block for receiving characteristic information of the caption data detected from the supplementary information, from the controller and displaying characteristics of the caption data on a screen.
[0019] In still another aspect of the present invention, a method for processing caption includes the steps of: dividing a received broadcast stream into video data, audio data, and supplementary information; judging whether caption data included in the video data is digital caption data or analog caption data on the basis of caption information included in the supplementary information; and selectively detecting at least one of parameters included in the caption information according to a result of the judgment; and extracting and decoding the caption data included in the video data on the basis of the detected parameter.
[0020] The step of selectively detecting at least one of parameters included in the caption information according to the result of the judgment, includes the step of: if the caption data included in the video data is digital caption data, detecting a caption service number that corresponds to the caption data from the caption information.
[0021] The step of selectively detecting at least one of parameters included in the caption information according to the result of the judgment, includes the step of: if the caption data included in the video data is analog caption data, detecting a standard of the caption data on the basis of the caption information; and detecting at least one of parameters included in the caption information according to the detected standard. At this point, if the detected standard of the caption data is the EIA 708, a field value that corresponds to the caption data is detected from the caption information and if the detected standard of the caption data is the SCTE 20 or the DVS 157, a field value and a VBI line number that correspond to the caption data are detected from the caption information.
[0022] The method for processing caption further includes the steps of: detecting characteristics of the caption data included in the video data on the basis of the caption information; and displaying the detected characteristics on a screen.
[0023] The characteristics of the caption data includes at least one among a number of caption services, a national language of a caption, a difficulty level of a caption, a picture ratio of a caption, a field value and a VBI line number that correspond to the caption data, provided by the caption data.
[0024] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] 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 embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0026] FIG. 1 is a view illustrating a bit stream of the general digital broadcast;
[0027] FIG. 2 is a view illustrating a syntax of caption information according to the present invention;
[0028] FIG. 3 is a block diagram illustrating a construction of a broadcast receiver according to the present invention; and
[0029] FIG. 4 is a flowchart illustrating a method for processing a caption according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0031] A digital cable broadcast under an open cable and a Cable Ready standards observes an ATSC standard. Therefore, the caption_service_descriptor the EIT or the PMT within the PSIP, included in the digital cable broadcast signal is prescribed by the ATSC standard (A65, Program and System Information Protocol for Terrestrial Broadcast and Cable).
[0032] FIG. 2 is a view showing a syntax of the caption_service_descriptor under the open cable and the Cable Ready standards according to the present invention. “descriptor_tag”, which is a parameter for checking a type of a descriptor, is described by 8 bits. “descriptor_length”, which is a parameter representing a length of the whole structure, is described by 8 bits. “number_of_services” represents a number of provided caption services and is described by 5 bits. “language” represents language information of a relevant caption, such as English for a service 1 and Spanish for a service 2 , and is a 3-byte language code under ISO 639.28, each letter of which is coded with 8 bits and inserted into a 24-bit field. “cc_type” represents a kind of caption. If cc_type==1, it is a digital caption (advanced caption) and if cc_type==0, it is an analog caption (analog caption under the EIA 708 or the SCTE 20 (DVS 157)). The “cc_type” is described by 1 bit. “analog_cc_type” represents a kind of an analog caption. If analog_cc_type==1, it means caption data transmitted through a line 21 of the VBI under the EIA 708, and if analog_cc_type==0, it means caption data transmitted through other line except the line 21 of the VBI according to the SCTE 20 or the DVS 157. “line_offset” represents a number of the VBI line including the caption data in case caption data under the SCTE 20 or the DVS 157 is transmitted, namely, in case the analog_cc_type==0, and is described by 5 bits. “line_field” represents whether the caption data is included in an even field or an odd field. That is, if line_field==0, it means the caption data is included in an odd field and if line_field==1, it means the caption data is included in an even field. “caption_service_number” represents 1-63 caption service numbers in case it is a digital caption, namely, in case cc_type==1. and is described by 6 bits. “easy_reader” is a flag representing whether it is a caption easily read by a user or not. “wide_aspect_ratio” is related to a screen ratio, and more particularly, is a flag representing whether a received caption data is intended for a 16:9 screen or not.
[0033] If cc_type==0, a received caption is an analog caption. As described above, for the analog caption, there exist an analog caption under the EIA 708 standard, and an analog caption under the SCTE 20 or the DVS 157 standard. However, since the analog caption under the EIA 608 standard is a pure analog caption, not a closed caption for a digital TV mentioned in the present invention, the analog caption under the EIA 608 standard is excluded. Therefore, an analog caption for the case cc_type==0, is either an analog caption under the EIA 708 standard or an analog caption under the SCTE 20 or the DVS 157 standard.
[0034] “analog_cc_type” represents whether a received caption is an analog caption under the EIA 708 standard or an analog caption under the SCTE 20 or the DVS 157 standard. If analog_cc_type==0, it means that the relevant caption is included in a video data region in form of user data under the SCTE 20 or the DVS 157, which are standards on the digital cable broadcast. In that case, since to which line of the VBI the received caption is assigned, is not known in view of characteristics of the cable broadcast, the line_offset describes to which line of the VBI the received caption is included. If analog_cc_type==1, it means that an analog caption under the EIA 708 standard is included in a video data region in form of user data. In that case, since the caption is assigned to a 21 st line of the VBI, a line_offset value is not required. Therefore, 5 bits assigned to the line_offset becomes a reserved bit and 1 bit is assigned to the line_field representing whether a caption is a caption included in an even field or a caption included in an odd field. If line_field==0, it means a caption is included in an odd field and if line_field==1, it means a caption is included in an even field.
[0035] As described above, whether a caption included in the digital cable broadcast is an analog caption or a digital caption is judged on the basis of information included in the caption_service_descriptor. Further, if the received caption is an analog caption, whether the caption is an analog caption under the EIA 708 standard or a caption for a cable broadcast under the SCTE 20 or the DVS 157 standard, is judged. If the received caption is a caption under the SCTE 20 or the DVS 157 standard, in which line of the VBI the caption data is included, is judged. If the received caption is a digital caption, information as to which service the caption includes among sixty-three services, is checked.
[0036] A broadcast station generates caption information including the above described various information and adds the caption information to a broadcast signal. A broadcast receiver detects caption information included in a broadcast signal provided from the broadcast station, and judges various characteristics of the received caption data on the basis of parameter values included in the detected caption information.
[0037] FIG. 3 is a block diagram illustrating a construction of a digital broadcast receiver according to the present invention. Referring to FIG. 3 , a MPEG demultiplexer 501 receives a MPEG-2 transport stream from a cable and decodes the transport stream so as to extract video data, audio data, and supplementary information. Further, the MPEG demultiplexer 501 detects an EIT and a PMT included in the supplementary information. The detected PMT is stored in a PMT buffer 502 and the detected EIT is stored in an EIT buffer 503 . Here, the detected PMT or EIT includes caption information, namely, caption_service_descriptor. A controller 504 receives caption information from the PMT buffer 502 or the EIT buffer 503 and detects caption data included in the transport stream on the basis of the caption information. A video parser 505 receives video data decoded by the demultiplexer 501 and separates the video data into user_data and MPEG-2 video data. An analog caption decoder 506 receives user_data from the video parser 505 and detects analog caption data from the user_data on the basis of a signal outputted from the controller 504 . A digital caption decoder 507 receives the user_data from the video parser 505 and detects digital caption data from the user_data on the basis of a signal outputted from the controller 504 . A MPEG-2 video decoder 508 decodes MPEG-2 video data generated by the video parser 505 . A graphic block 510 outputs a signal for generating a GUI (graphic user interface) such as an OSD (on screen display) menu including information provided from the controller 504 . The graphic block 510 displays, on a screen, various characteristics of the received caption data, for example, a number of caption services, a national language of a caption, a type and a standard of the received caption data, VBI line information and field information that correspond to the caption data, a difficulty level of the caption, a picture ratio of the caption. A video combiner 509 receives analog caption data from the analog caption decoder 506 or receives digital caption data from the digital caption decoder 507 . Further, the video combiner 509 receives video data from the MPEG-2 video decoder 508 and receives a signal outputted from the graphic block 510 . The video combiner 509 combines the received signals so as to generate data that will be possibly displayed. A video reconstructor 511 encodes an analog caption data decoded by the analog caption decoder 506 , at a 21 st line of the VBI.
[0038] Operation of the digital broadcast receiver as described above according to the present invention will now be described. FIG. 4 illustrates a method for processing a caption according to the present invention.
[0039] If a MPEG-2 transport stream transmitted through a cable is received, the MPEG demultiplexer 501 divides the received transport stream into video data, and audio data, supplementary information. The supplementary information includes a PSIP defining electronic program guide (EPG) and system information (SI). The PSIP includes a plurality of tables including information for transmitting/receiving A/V (audio/video) data made in a MPEG-2 video and AC-3 (audio coding-3) audio formats, and information regarding channels of each broadcast station and information regarding each program of channel. Among them, information regarding the PMT and information regarding the EIT are stored in the PMT buffer 502 and the EIT buffer 503 , respectively. Under the ATSC standard, the digital cable broadcast signal must include a caption_service_descriptor in its PMT or EIT.
[0040] The controller 504 reads a caption-related option stored in a memory (not shown) and determines a caption-related option selected by a user (S 11 ). For example, the caption-related option includes various options such as “caption off”, “caption service selection (cc1, cc2, cc3, . . . )”, “English caption display”, “Korean caption display”, “size of caption”, “color of caption”. If a user selects “caption off”, the controller 504 does not display the received caption. If a user selects “English caption display”, the controller 504 controls the caption decoders 506 and 507 so that only the caption written in English may be displayed on a screen. Further, the controller 504 controls the caption decoders 506 and 507 so that the received caption data may be processed according to a set size and a set color of a caption.
[0041] The controller 504 receives the caption information and judges characteristics of the received caption data on the basis of parameter values included in the caption information (S 12 ). The controller 504 judges a number of caption services on the basis of the caption information. For example, the controller 504 judges whether a synchronous caption, an asynchronous caption service, a letter information service are provided. The controller 504 judges a language of the received caption on the basis of the caption information. For example, the controller 504 judges whether the received caption is English, Japanese, or Korean. The controller 504 judges a type of the received caption data on the basis of the caption information. For example, the controller 504 judges whether the received caption data is digital caption data or analog caption data (S 13 ). The controller 504 determines a standard of the received caption data on the basis of the caption information. For example, if the received caption data is analog caption data, the controller 504 judges whether the received caption data is caption data under the EIA 708 standard or the SCTE 20 or the DVS 157 standard. Further, the controller 504 judges a VBI line number and a field including the received caption, a difficulty level of the received caption, and a picture ratio of the received caption on the basis of the caption information.
[0042] To judge whether the received caption data is digital caption data in the step of S 13 , the controller 504 judges whether the digital caption data is included in the video data on the basis of the caption information.
[0043] If digital caption data under the EIA 708 is included in the video data (if cc_type==1), the controller 504 detects a service ID that corresponds to the caption data from the caption information (S 14 ) and transmits the detected service ID to the digital caption decoder 507 . The service ID can be known from a capto_service_number included in the caption information. The digital caption decoder 507 extracts and decodes caption data that corresponds to the service ID from user_data of a picture header transmitted from the video parser 505 (S 15 ). Subsequently, the extracted caption data is transmitted to the video combiner 509 . The video combiner 509 combines the extracted caption data, video data outputted from the MPEG-2 video decoder 508 , and signals outputted from the graphic block 510 .
[0044] If analog caption data is included in the video data (if cc_type==0), the controller 504 judges whether the received caption data is analog caption data (analog_cc_type==1) under the EIA 708 standard or analog caption data (analog_cc_type==0) under the SCTE 20 or DVS 157 standard (S 16 ). At this point, the controller 504 determines a standard of the received analog caption data on the basis of the caption information.
[0045] If the received caption data is analog caption data under the SCTE 20 or the DVS 157, the controller 504 checks VBI line information described in 5 bits by a line_offset included in the caption information. The VBI line information represents a position of the caption data. Further, the controller 504 judges a field where the caption data exists on the basis of line_field information included in the caption information. If line_field==0, the caption data exists in an odd field and if line_field==1, the caption data exists in an even field. After that, the controller 504 transmits the above checked VBI line information and the line field information to the analog caption decoder 506 . If the received caption data is analog caption data, user_data outputted from the video parser 505 is not processed by the digital caption decoder 507 . The analog caption decoder 506 finds out (S 18 ) analog caption data made in the SCTE 20 or the DVS 157 standard from user_data inputted from the video parser 505 on the basis of the VBI line information and the line field information, and decodes the analog caption data (S 19 ). The analog caption data found by the analog caption decoder 506 is transmitted to the video combiner 509 . The video combiner 509 combines the analog caption data, video data outputted from the MPEG-2 video decoder 508 , and signals outputted from the graphic block 510 . Signals outputted from the video combiner 509 are transmitted to the video reconstructor 511 . The video reconstructor 511 reconstructs a caption by encoding analog caption data outputted from the analog caption decoder 506 , at a VBI 21 st line. The reconstruction of a caption is to prevent analog caption data from being an open caption in case of storing data, as it is, outputted from the video combiner 509 in a storage medium such as a VCR (video cassette recorder).
[0046] If the received caption data is analog caption data under the EIA 708 standard (if analog_cc_type==1), the controller 504 transmits line_field information included in the caption information to the analog caption decoder 506 . Since analog caption data under the EIA 708 standard is positioned at a VBI 21 st line, a line_offset value is not required. At this point, the digital caption decoder 507 extracts a 2-byte analog data in user_data including digital caption data from the video parser 505 and transmits the analog data to the analog caption decoder 506 . Subsequently, the analog caption decoder 506 finds out (S 17 ) analog caption data present in a VBI 21 st line from the 2-byte analog data on the basis of the line_field information and decodes the analog caption data (S 19 ). The found analog caption data is combined with video data from the MPEG-2 video decoder 508 and signals from the graphic block 510 by the video combiner 509 . The video reconstructor 511 reconstructs a caption by encoding analog caption data from the analog caption decoder 506 at a VBI 21 st line.
[0047] If analog caption data under the EIA 708 and analog caption data under the SCTE 20 and the DVS 157 are all present in the user_data, the analog caption data under the EIA 708 is processed. Further, if digital caption data under the EIA 708 and analog caption data under the EIA 708 are all present in the user_data, the digital caption data is processed.
[0048] As described above, the present invention judges a type of caption data on the basis of caption information included in the received broadcast signal and automatically processes the caption data according to the type, thereby providing convenience to a user. Further, the present invention judges various characteristics of the received caption data such as a standard of caption data, a number of caption services being received and provides the characteristics to a user. Furthermore, the present invention can store caption-related options selected by a user and display the caption being received according to the caption-related options.
[0049] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A digital cable broadcast receiver and a method for automatically processing caption data of various standards and types, is disclosed. The digital broadcast receiver includes: a demultiplexer for dividing a received broadcast stream into video data, audio data, supplementary information; a controller for determining whether caption data included in the video data is digital caption data or analog caption data on the basis of caption information included in the supplementary information, and outputting a control signal according to a result of the determining; a digital caption decoder for extracting and decoding digital caption data from the video data according to the control signal; and an analog caption decoder for extracting and decoding analog caption data from the video data according to the control signal.
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BACKGROUND OF THE INVENTION
This invention is directed to a coupling for connecting a threaded rod to a second element having a bore provided therein and more specifically, to a coupling for quickly connecting the threaded push rod of an air motor to the clevis of a brake actuating lever and automatic slack adjustor on a vehicle assembly line without the need for any other tools.
More particularly, this invention is directed to a coupling for quickly connecting the threaded push rod of an air motor to the clevis of a brake actuating lever and automatic slack adjustor of the type disclosed in U.S. Pat. No. 3,949,840 which issued to J. C. Cumming, et al, on April 13, 1976. Such a device will hereinafter be referred to as a brake actuating lever which, for purposes of this invention, will be used to describe a brake actuating lever that includes an automatic slack adjusting mechanism as well as a brake actuating lever without an automatic slack adjusting mechanism. Other brake adjusting levers of the type with which the present invention may also be utilized are described in U.S. Pat. Nos. 3,507,369, 3,526,303, U.S. Pat. No. Re. 26,965, U.S. Pat. Nos. 3,121,478, 3,351,164 and 3,371,755.
The brake actuating levers which the present invention is particularly directed are utilized primarily in a rotary cam actuated internally expanding brake assembly. The brake actuating lever is splined at one end to a shaft which rotates the cam and the other end is connected by means of a clevis to the push rod of an air motor. Various connections have been used between the threaded push rod of the air motor and the clevis. In one conventional connection the threaded push rod is threaded into a tabbed bore provided in the clevis and upon adjustment to provide the proper length, a locknut is threaded down and seated tight against the surface of the clevis to prevent loosening of the push rod. This requires rotary movement of the push rod relative to the clevis or the clevis relative to the push rod and may require either removing the clevis from the brake actuating lever or the push rod from the air motor. Removal or disassembly of component parts, of course, requires whatever additional steps may be necessary to reassemble those parts at the point of installation on the vehicle assembly line.
One approach to avoid such disassembly has been to provide both a locknut and an externally threaded ferrule or yoke adaptor to the threaded push rod. During assembly the push rod is brought into juxtaposition with a threaded bore provided to the clevis. The yoke adaptor is threaded to the bore in the clevis and then the locknut is tightened against the yoke adaptor to prevent disassembly during service. This avoids the need to disassemble parts of the brake actuating lever or the air canister, but it still requires the use of tools in tightening two separate nut members in a relatively confined space on a vehicle assembly line.
SUMMARY OF THE INVENTION
The present invention avoids certain of the foregoing problems of the prior art by providing a coupling for quickly connecting a threaded push rod to the clevis of a brake actuating lever which comprises the combination of a collar having an internal bore threaded for engagement with the push rod, a head at one end of the collar and a recess forming a shoulder spaced from the head, latching means carried by the clevis and biased into a first position extending internally of a bore provided to the clevis and latch displacing means carried by the collar adjacent to the shoulder. During assembly the latch displacing means serves to displace the latching means upon axial insertion of the collar into the bore and the latching means returns to its first position and engages the shoulder provided to the collar to prevent withdrawal of the collar from the bore.
In the preferred embodiment, the latching means is a spring carried by the clevis and the collar is comprised of a cylindrical body having a head at one end, a tapered, conical surface at the other end and a spring engaging groove extending circumferentially around the cylindrical body intermediate the head and the tapered, conical surface. Upon insertion of the collar to the bore provided to the clevis, the tapered, conical surface displaces the spring latching means until such time that the spring latching means is biased into the spring engaging groove thereby preventing withdrawal of the collar from the bore.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like reference numerals refer to like parts:
FIG. 1 is a side elevation showing an assembly of a threaded push rod to the clevis of a brake actuating lever;
FIG. 2 is a top plan view, partly in section, showing part of the assembly of FIG. 1;
FIG. 3 is a side elevation of the collar shown in FIG. 2;
FIG. 4 shows another element of the assembly of FIGS. 1 and 2;
FIG. 5 is a top plan view similar to FIG. 2 showing an alternate embodiment of the invention; and
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 the present invention is shown in the form of an assembly of a threaded push rod connected to a cylindrical bore provided to the clevis of a brake actuating lever. With reference to FIG. 1 there is shown an air motor 10 secured to a plate 11 which in turn is rigidly secured to a brake support or directly to a vehicle axial. A push rod 12 extending from the air motor 10 is connected to the clevis 14 of which is pivotally connected to the brake actuating lever 15 by means of a pin 16 and cotter key 18. The brake actuating lever 15 in turn is splined to the rotary actuating shaft 19 of a cam brake assembly not shown.
The brake actuating lever 15 is described in greater detail in U.S. Pat. No. 3,949,840 but consists essentially of an elongated housing forming a lever 20 having a worm gear 21 at one end. The worm gear 21 is internally splined for connection to the rotary actuating shaft 19. A worm, provided internally of the lever 15, engages the worm gear 21 and is connected to a rod 22 by means of an automatic adjusting mechanism not shown. The rod 22 is pivotably connected to the end of the clevis 14 by means of a pin 24 and cotter key 25. Air supplied to the motor 10 extends the push rod 12 thereby rotating the brake actuating lever 15 clockwise about the rotary cam shaft 19 to the position shown by the phantom lines. When the air pressure is released from the motor 10 the assembly returns to the position shown in FIG. 1. In the event the arcuate movement of the brake actuating lever 15 is greater than some predetermined movement considered satisfactory for normal running clearance, the automatic adjusting mechanism will rotate the worm, the worm gear 21 and the rotary actuating shaft to a position providing the desired running clearance between the brake shoes and a surrounding brake drum.
The coupling between the push rod 12 and the clevis 14 is best shown by FIG. 2. The clevis 14 is provided with a cylindrical bore 26 having a recess in the form of a groove 28 extending circumferentially around the internal cylindrical wall of the bore. A split spring ring 29 such as that shown by FIG. 4 is provided to the groove 28. The internal diameter of the split spring ring 29 is slightly less than the internal diameter of the bore 26. A locknut 27 and a collar 30 such as that shown by FIG. 3, are threaded to the push rod 12. The collar is comprised of a cylindrical body portion 31 having a hexagonal head 32 at one end, a conical surface 34 at the other end, and a groove 35 extending circumferentially around the cylindrical body 31 intermediate the hexagonal head 32 and the conical surface 34. The conical surface 34 is tapered to gradually increase to the diameter of the cylindrical body 31 of the collar 30 and the groove provides a shoulder 36 adjacent the conical surface 34. The split, spring ring 29 is carried by the clevis groove 28 and extends partly into the collar groove 35 thereby providing an interference fit between the clevis bore 26 and the collar 30. Any attempt to axially withdraw the collar 30 from the bore 26 will cause the shoulder 36 of collar groove 35 to engage or abut the split, spring ring 29 which prevents further movement or axial withdrawal of the collar 30 and push rod 12 from the clevis bore 26.
On a vehicle assembly line, the air motor 10 and the brake actuating lever 15 may be provided to the frame or their respective related components at different points in time and/or at different locations on the line. The motor 10 and the actuating lever 15 may be obtained from different sources and the brake actuating lever 15 may be provided to the OEM as an integral part of a rotary cam actuate brake assembly. In any event, the present invention provides for a quick connection of the air motor push rod 12 to the clevis 14 of a brake actuating lever 15 at any predetermining point on the assembly line.
In practice, the locknut 27 and collar 30 are threaded to the push rod 12 but only to the extent that the push rod 12 is flush with or extends only slightly from the tapered, conical end of the collar 30. The locknut 27 may be tightened to the collar 30 at that time. Then at the appropriate location on the assembly line, the push rod and collar 30 are manually, axially inserted in the clevis bore 26 to effect the desired connection.
Upon axial insertion of the collar 30 the tapered, conical surface 34 connects the split, spring ring 29 and expands that ring forcing it back into the groove 28 provided to the bore 26, thereby permitting the cylindrical body portion 31 of the collar to slidably pass the expanded split ring until the collar groove 35 becomes aligned with the groove 28. At this point, the split, spring ring 29 will snap into the groove 35 and provide an interference fit between the grooves 28 and 35 thereby preventing withdrawal of the collar. Once assembled the collar 30 cannot be removed from the clevis 14 but the push rod 12 may be removed for normal service purposes by loosening the locknut 27 and rotating the hexagnol head 32 of the collar 30 to back the push rod 12 out of the collar.
An alternate embodiment is shown by FIGS. 5 and 6. In FIGS. 5 and 6, elements identical to those previously described are identified by the same reference numerals.
The clevis of the embodiment shown in FIGS. 5 and 6 is slotted across the top and bottom as shown at 40 and 41 to provide access from the exterior of the clevis to the interior of the cylindrical bore 26. The clevis 14 is also drilled and tapped at 42 to accommodate a machine screw 44. A spring 45, best shown in FIG. 6 is formed at its midpoint with a loop that fits around the shank of the machine screw 44 and is trapped between the head of the screw and the clevis body proper. The ends of the spring 45 extend through the slots 40 and 41 across the body of the clevis and are formed with detents at 46 and 48. The detents 46 and 48 project into the cylindrical bore 26. During assembly a locknut 27 and a collar 30' are threaded to the end of the push rod 12 in the same manner as previously described for the embodiment of FIGS. 1 and 2. The collar 30' is tapered or chamferred at the end 34'. As the push rod 12 and collar 30' are axially inserted to the cylindrical bore 26, the tapered outer end 34' of the collar contacts the detents 46 and 48 provided to the spring 45 and expands the two legs of the springs 45 out into the slot 40 and 41 until the groove 35' provided circumferentially around the collar 30' is aligned with the slots 40 and 41. When the groove 35' becomes axially aligned with the slots 40 and 41, the detents 46 and 48 are biased into the groove 35' and prevent the collar 30' from being axially withdrawn from the bore 26.
The springs 29 and 45 of the two described embodiments thus constitute latching means carried interiorly of the cylindrical bore provided to the clevis which are displaced by the tapered, conical surface provided to the collar 30 or the tapered end provided to the collar 30' to pass a portion of the cylindrical body of each respective collar until the grooves provided to the collar align with the spring biased latching means.
Both embodiments provide the desired quick connect assembly of a push rod to a clevis. The embodiment of FIGS. 1 and 2 offers the additional advantage that the split, spring ring can be provided internally of the clevis bore without requiring an additional element such as the machine screw of the FIGS. 5 and 6 embodiment which might be accidentally removed or lost during servicing.
The invention may also be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing description is, therefore, to be considered as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and all changes which come within the meaning and range of equivalency of the claims are, therefore, intended to be embraced thereby.
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A quick connect coupling for connecting a threaded push-rod to a clevis of a brake actuating lever, the coupling comprises the combination of a collar having an internal bore threaded for engagement with the push rod, a head at one end of the collar and a recess forming a shoulder spaced from the head, latching means carried by the clevis and biased into a first position extending internally of a bore provided to the clevis and latch displacing means carried by the collar adjacent to the shoulder. During assembly the latch displacing means serves to displace the latching means upon axial insertion of the collar into the bore and the latching means returns to its first position and engages the shoulder provided to the collar to prevent withdrawal of the collar from the clevis bore.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to apparatuses and methods for locating tools on pedestals and, in particular embodiments, to a novel apparatus and method for conveniently locating a tool belt with tools on a top step of a ladder or stepladder.
2. Description of Related Art
Craftspersons (professionals or amateurs) are often faced with the task of working with tools or other items, while on or around ladders. In some situations, this involves careful balancing, while holding tools or items and maneuvering up and down the ladders. In other situations, craftspersons wear or carry tool belts, while maneuvering up and down the ladder. Tool belts can get snagged in the steps of the ladder. Aside from the inconvenience this can cause, there is also the danger that craftspersons might fall off or knock over the ladder as a result of losing their balances or snagging their tool belts.
A wide variety of devices have the purpose of making it easier for craftspersons to use their tools around ladders. Some devices use bags that fit over the top step of a ladder (see U.S. Pat. No. Des. 317,206). Such bags have pockets in them for inserting various tools. Some devices include a box-type enclosure on top of the bag for placing tools (see U.S. Pat. No. 4,356,854).
Another example of a traditional solution to handling tools around ladders is to have a box attached to one side of the top portion of the ladder (see U.S. Pat. No. 2,911,133). Such a box attaches to the ladder with specially designed holding bars.
Finally, one device provides the capability of securing a tool box on the top step of a ladder by the use of a mounting clip to fit into a nonstandard opening of a modified tool box (see U.S. Pat. No. 4,653,713).
However, none of the above described devices has succeeded in accommodating craftspersons who would like to keep their tool belts and/or tool boxes and other items conveniently near them, while they are working on ladders.
SUMMARY OF THE DISCLOSURE
In accordance with preferred embodiments of the present invention, an apparatus and method is capable of supporting a belt around a pedestal (a pedestal is a structure for providing support, e.g. the top step of a ladder, or even the top of a barstool).
According to one embodiment of the invention, an apparatus for holding articles on a pedestal is operable with a belt, such as a tool belt. The apparatus comprises a container having a bottom surface and an outer peripheral surface. The bottom surface of the container is configured for placement on an upper surface of the pedestal. One or more belt loops are attached to the outer peripheral surface of the container for supporting a belt adjacent the outer peripheral surface of the container.
In another embodiment of the invention, the dimensions of the outer peripheral wall of the container are substantially similar to the dimensions of the upper surface of the pedestal. In addition, at least one belt loop extends below the bottom surface of the container to overlap a top sidewall of the pedestal upon the bottom surface of the container being placed on the upper surface of the pedestal. In this arrangement, a belt supported by the belt loop overlaps the upper sidewall of the pedestal and can be tightened around the upper sidewall to help secure the container to the upper surface of the pedestal.
Another embodiment of the invention, which is also operable with a belt and a pedestal, comprises an apron covering the container. A belt loop attaches to the outside surface of the apron for supporting a belt adjacent to the outside surface of the apron. Preferably, the apron has an edge overhang that extends below the bottom surface of the container to overlap the top sidewall of the pedestal upon the bottom surface of the container being placed on the upper surface of the pedestal. This edge overhang stabilizes the container on the pedestal.
In another variation of this embodiment, at least one belt loop extends below the bottom surface of the container to overlap the top sidewall of the pedestal upon the bottom surface of the container being placed on the upper surface of the pedestal. This also stabilizes the container on the pedestal.
In any of the above discussed embodiments of the invention, the belt loop can have a first end which is permanently attached to the apron, and a second end, which is attachable to the container by a releasable attaching means.
Also, in any of the above discussed embodiments of the invention, one or more straps are preferably attached to the apron or the container. Such straps can extend underneath the upper surface of the pedestal for strapping the container to the pedestal.
The above discussed and many other features and attendant advantages of the present invention will become better understood by reference to the following detailed description, when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view showing the individual parts of a tool belt carrier (an apron and a tool box) in conjunction with a tool belt and a ladder, in accordance with an embodiment of the present invention.
FIG. 2 is a perspective view of an assembled tool belt carrier as shown in FIG. 1.
FIG. 3 is a perspective view showing a tool belt carrier, in accordance with another embodiment of the invention.
FIG. 4 is a perspective view showing a tool belt carrier comprising an apron adaptable to tool boxes of various sizes, in accordance with another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.
In the figures discussed below, the same or equivalent items shown in the figures are identified by the same reference numbers.
Illustrated in FIGS. 1 & 2 is a ladder mounted tool belt carrier according to a preferred embodiment of the invention, as used in conjunction with a standard ladder 10. FIG. 1 provides an overview of how the preferred embodiment cooperates with a ladder 10 and a tool belt 46.
The ladder 10 has a top step 12, defining an upper surface 14, as well as a peripheral edge 16. A tool box 18 having a bottom surface 20, roughly the size of the upper surface 14 of a standard top step 12, is placed on the top step 12 of the ladder 10. Standard ladders 10 typically have top steps 12 with upper surfaces 14 in the range of 4-6 inches by 12-14 inches. The tool box 18 has a handle 22, an outer peripheral surface 21, and an inside surface 26.
An apron 28 (made of, for example, canvas, plastic, nylon, leather, a combination thereof, or other material suitable for supporting an attached tool belt 46 with accessories, as discussed below) fits around the outer peripheral surface 21 of the tool box 18. The apron 28 preferably is riveted to the outer peripheral surface 21 of the tool box 18. Alternatively, the apron 28 could be attached to the tool box 18 with any suitable securing means including, but not limited to screws, bolts, adhesives, stitching, snaps, or the like.
The apron 28 has at least one belt loop and, preferably, multiple belt loops 44 located adjacent to the outside surface 36 of the apron 28. These belt loops 44 are dimensioned to receive a belt (preferably a tool belt 46) strapped therethrough. Tool belt 46 may be a standard tool belt provided with pouches 48 and other means for holding tools, e.g. a hammer 50 and/or paraphernalia, such as screws, nails, etc. In further embodiments, clips, hooks or other belt supporting structures may be used as an alternative to belt loops. However, for simplifying the present disclosure and claims, the term "belt loops" will be understood to refer to any suitable means for supporting a belt.
FIG. 2 shows an assembled tool belt carrier as shown in FIG. 1. FIG. 2 illustrates the tool box 18 with an apron 28 riveted with rivets 30 (or attached by other means, as discussed below) to the outer peripheral surface 21 of the tool box 18. The tool box 18 is situated on the top step 12 of the ladder 10. As in FIG. 1, the apron 28 has belt loops 44 for supporting the tool belt 46.
The apron 28 has an edge overhang 62. The edge overhang 62 provides additional support to the tool box 18. The edge overhang 62 extends over at least part of the step sidewall 64 (only the uncovered portion of the step sidewall 64 is shown in FIG. 2) on all four sides of the rectangular top step 12. As a result, the edge overhang 62 of the apron 28 inhibits the tool box 18 from sliding off the top step 12. It is recommended that the user of the ladder be aware of the total weight limit of the ladder (usually specified by the manufacturer of the ladder) and not exceed the weight limit with the additional weight of the tool box, tool belt and any tools or items held by the same.
The belt loops 44, shown in FIG. 2, extend beyond the peripheral edge 16 (not shown in FIG. 2, because it is covered by apron 28, but shown in FIG. 1). With this arrangement, the tool belt 46, when secured by the belt loops 44, has a bottom edge 68 that extends beyond the peripheral edge 16. The rigidity of the tool belt 46 and the ability of the tool belt 46 to be tightened around the step sidewall 64 helps secure the apron 28 and the tool box 18 and the tool belt 46 to the ladder 10. Therefore, the tool belt bottom 68 further inhibits the tool box 18 from sliding off the top step 12 of the ladder 10. As a result, the likelihood of someone accidentally pushing the tool box 18 off the ladder 10 is reduced.
Furthermore, embodiments of the invention make it possible for the craftsperson to conveniently locate a tool belt 46, by securing the tool belt 46 with the belt loops 44 of the apron 28. To properly secure the tool belt 46 with the belt loops 44, the tool belt 46 is inserted through the belt loops 44 and secured to the tool belt 46. Additionally, if desired, any tools and pouches 48 can be attached to the tool belt 46.
Consequently, a craftsperson is able to conveniently secure a tool belt 46 and a tool box 18 to the top step 12 of a ladder 10 and to freely move on the ladder 10 without a heavy tool belt 46 or a tool box 18 hindering the craftsperson's movement. Moreover, the tools on the tool belt 46 are conveniently located on the top step 12 of the ladder 10 and readily accessible to anybody working on or near the ladder 10. Other embodiments, one of which is illustrated in FIG. 3, do not include an apron edge overhang 62 and/or belt loops 44 which extend beyond the top step peripheral edge 16.
To further reduce the likelihood of the tool box 18 being accidentally pushed off the ladder 10, the apron 28 preferably has straps 34 for extending under the top step 12 and strapping the tool box 18 to the top step 12. In the preferred embodiment shown in FIG. 1, there are four straps 34 attached in pairs to the outside apron surface 36, with two of the four straps 34 attached on the opposite side of the apron 28 with respect to the other two straps 34.
Each strap 34 has a first strap end 38 and a second strap end 40. The first strap ends 38 are attached to the apron 28. The straps 34 have connectors 42 (such as snaps, buckle connectors, hook and loop fastening material, for example, as sold under the trademark "Velcro," or other suitable fasteners) on their second strap ends 40, such that the connector 42 ends of straps 34 on opposite sides of the apron 28 mate underneath the top step 12 of the ladder 10 to strap the tool box 18 to the top step 12 of the ladder 10.
Alternatively, the straps 34 can be without connectors 42. In that case, oppositely located second strap ends 40 can be tied together underneath the top step 12 to secure the tool box 18 to the top step 12. Of course, with or without connectors 42, a single pair of straps 34 would be sufficient to strap down the tool box 18. Another alternative, is to have one or more straps 34 attached at a first strap end 38 to one side of the apron 28 and releasably secured at a second strap end 40 to the apron 28 or to the tool box 18.
In another embodiment of the present invention, as illustrated in FIG. 3, the apron 28 covers the inside surface 26 of the tool box 18. The apron 28 is shaped such that it fits snugly against the inside surface 26 of the tool box 18.
To maintain the apron 28 in place, the apron 28 is rivetted with rivets 30 to the inside surface 26 of the tool box 18. Of course, the apron 28 could be attached to the tool box 18 by some other means, as, for example, screws, nails, adhesives, or other coupling means suitable to keep the apron 28 attached to the tool box 18.
In another embodiment of the invention, the belt loops 44 may be permanently affixed to the apron 28 or may be attached to the apron 28 by means which allow one or both loop ends (54 and/or 56) to be selectively disconnected from the apron 28. Such means may include, but are not limited to snaps, buttons, clips, hook and loop fastening material, or the like. Thus, the craftsperson could, for example, snap a tool belt 46 into place around the tool box 18 without removing from the tool belt 46 any of the pouches 48 or tools that would not fit through the belt loops 44.
Preferably, the belt loop lower ends 54 are permanently attached to the apron 28, whereas the belt loop upper ends 56 are connected by disconnectable means. This reduces the chance that the disconnectable ends of the belt loops 44 will be inadvertently disconnected due to the weight of the tool belt 46 bearing down directly on the belt loop snap 58 (shown in FIG. 3).
To further enhance the convenience and safety, another preferred embodiment of the invention is provided with a carrier strap 60 (as illustrated in FIG. 3) attached to the sides of the tool box 18 or to the apron 28. The carrier strap 60 can be used as a shoulder strap to enable a craftsperson to support the tool box 18 from his or her shoulder.
Finally, FIG. 4 illustrates a further embodiment of the invention having a feature that allows the apron 28 to be adaptable to tool boxes 18 of various sizes. FIG. 4 shows an apron 28 made up of a first apron portion 66 and a second apron portion 70. The first apron portion 66 and the second apron portion 70 have belt loops 44 attached to them. Additionally, a first handle strap 72 and a second handle strap (not shown because of the perspective nature of the view shown in FIG. 4) attach to each end of the first apron portion 66.
Each end of the second apron portion 70 has connectors, such as strings, snaps, buttons, clips, hook and loop fastening material, a combination thereof, or the like. A first 74 and a second 76 connectors attached at one end of the second apron portion 70 are illustrated in FIG. 4. And at the other end of the second apron portion 70 there are attached a third (not shown because of the perspective nature of the view shown in FIG. 4), and a fourth (not shown because of the perspective nature of the view shown in FIG. 4) connectors.
The first 72 and second (not shown) handle straps are pulled over a first 78 and second (not shown) handle hinges, respectively, and connected to the first 74 or second 76 connector, and to the third or fourth connector (not shown), respectively, depending on the size of the tool box 18. The first 72 and second (not shown) handle straps prevent (in addition to a tool belt 46 secured with the belt loops 44 and tightened around the tool box 18) the apron 28 from sliding off the tool box 18 under the weight of the tool belt 46. And the availability of more than one connector at each end of the second apron portion 70 enables the craftsperson to adjust the first 72 and second (not shown) handle straps in accordance with the size of the tool box 18.
To further tighten the apron 28 around the tool box 18, a first lower strap 80 and a second lower strap (not shown because of the perspective nature of the view shown in FIG. 4) attach to each end of the first apron portion 66. Similarly to the first 72 and second (not shown) handle straps, the first 80 and second (not shown) lower straps are located on opposite sides of the apron 28.
Connectors (such as strings, snaps, buttons, clips, hook and loop fastening material, a combination thereof, or the like) are attached to each end of the second apron portion 70 for fastening the first 80 and second (not shown) lower straps to the second apron portion 70. The first lower strap 80 connects to a fifth 82 or to a sixth 84 connector, depending on the size and shape of the tool box 18. The second lower strap (not shown) connects to a seventh (not shown because of the perspective nature of the view shown in FIG. 4) or eighth connector (not shown because of the perspective nature of the view shown in FIG. 4), also depending on the size and shape of the tool box 18.
One advantage of the embodiment of the invention illustrated in FIG. 4 is that the apron 28 may be adapted to a variety of tool boxes 18 of different sizes. This is possible because the two apron portions, 66 and 70, can be spaced with respect to each other at variable distances. That variable spacing is accomplished by fastening the handle straps 72 and the lower straps 80 to the appropriate connectors.
In another embodiment of the invention, the apron 28 has only one portion (as opposed to a first 66 and a second 70). However that portion is sufficiently long to wrap around the tool box 18, as both portions together do in FIG. 4. A first handle strap 72 is secured across the first handle hinge 78 for supporting the apron 28 from and tightening the apron 28 around the tool box 18. In a variation of that embodiment, the apron 28 has a second handle strap and an associated connecting means (as discussed above with respect to the two-portion apron 28) attached to the middle region of the apron's outside surface 36 for securing the apron 28 to the second handle hinge (not shown).
The apron 28 in FIG. 4 can be equipped with straps 34, as in FIG. 1, for additional means of securing the tool box 18 to the pedestal, in particular to a top step 12 of a ladder 10. Moreover, by draping beyond the bottom edge 86 of the tool box 18 shown in FIG. 4, the apron 28 provides an edge overhang 62. As in FIGS. 1 & 2, that edge overhang 62, functions as an additional means of securing the tool box 18 to the top step 12 of the ladder 10.
Another embodiment of the invention is an apron 28 having any of the forms discussed above, with one or more belt loops 44 for securing a belt, preferably a tool belt 46, but without a tool box 18. This embodiment fits directly over or around a pedestal, such as a top step 12. A further embodiment has an apron 28, but without any belt loops. Nevertheless, a belt is used to tighten the apron 28 around the pedestal or around the tool box 18. In yet a further embodiment, belt loops, hooks or other belt supporting structures, are coupled directly to the pedestal (such as to the peripheral side of the top step of a ladder) to support a tool belt directly to the ladder.
In further embodiments of the invention, a tool box 18 with at least one belt loop (or other suitable belt supporting structure, including, but not limited to hooks, clips or the like) attached directly to the outer surface of the box for securing a tool belt 46, but without an apron 28.
The belt loop(s) or other belt supporting structure extend below the top edge of the pedestal or are otherwise arranged such that the belt extends below the top edge of the pedestal. This allows the belt to extend around the peripheral side surface of the top step of the pedestal so as to be tightened around the peripheral side surface. In addition, straps (such as straps 34 discussed above) may be attached directly to the outer surface of the box 18, without an apron 28. The straps 34, belt loop(s) or other belt supporting structure may be attached to the box 18 by any suitable securing means including, but not limited to rivets, screws, bolts, adhesives or the like.
A further embodiment of the invention would include not only a tool box 18 and an apron 28, but also a pedestal on which are situated the tool box 18 with the apron 28 attached to the tool box 18.
Having thus described exemplary embodiments of the present invention, it should be understood by those skilled in the art that the above disclosures are exemplary only and that various other alternatives, adaptations and modifications may be made within the scope of the present invention.
The presently disclosed embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are, therefore, intended to be embraced therein.
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An improved apparatus and method for holding articles on a ladder, operable with a combination of a tool belt, a tool box, and/or an apron. In one combination that uses all of these items, the apron has belt loops. The apron attaches to the sidewall of the tool box. The belt loops secure the tool belt. And the tool box with the apron and the tool belt attached is situated on the top step of the ladder. To stabilize the tool box on the top step, the apron has an edge overhang, which extends over at least part of the sidewall of the top step. For further stabilization, the belt loops also extend over at least part of the sidewall of the top step, thereby allowing the tightening of the tool belt around the sidewall of the top step. Additionally the tool box is stabilized on the step ladder by straps attached to either the tool box or to the apron itself. The straps extend underneath the top step of the step ladder.
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[0001] It is known from the literature that in polymers containing sulfinate groups SO2Li the sulfinate groups can be cross-linked by di- or oligohalogenoalkanes with alkylation of the sulfinate group to the sulfone group. This crosslinking method can be used to cross-link ionomer membranes in order to reduce the membrane swelling which leads to a better mechanical and thermal stability of the membranes in the respective membrane process (for example electrodialysis, diffusion dialysis, membrane fuel cells (hydrogen membrane fuel cells, direct methanol fuel cells)). One can produce two different types of in such a way cross-linked ionomer membranes:
[0002] 1) The sulfonated polymer is dissolved together with the sulfinated polymer in a suitable, often dipolar aprotic solvent and a dihalogeno cross-linker or oligohalogeno cross-linker if necessary is added, for example 1,4-diiodobutane. During the solvent evaporation the cross-linking reaction takes place.
[0003] 2) A polymer, which contains both sulfinate and sulfonate group (produced by partial oxidation, for example, of the polymeric sulfinate with NaOCl, KMnO 4 , H 2 O 2 etc.), is dissolved in a suitable dipolar aprotic solvent and a dihalogeno cross-linker or oligo halogeno cross-linker if necessary is added, for example 1,4-diiodobutane. During the solvent evaporation the cross-linking reaction takes place. Up to now however only sulfinated polymers are known from the literature, which are prepared from the reaction of organometallated polymers with Sulphur dioxide (for example lithiated polysulfone from the reaction of polysulfone with butyl- or phenyllithium). However, not every type of polymers can be treated with organometallic reagents since the organometallic reagents react with functional groups of the polymers and are able to destroy the polymers. Organometallic reagents react with the carbonyl group, for example, so that high performance thermoplastics of the polyetherketone family containing the carbonyl group in the main chain for example (Polyetherketone PEK Victrex®, polyetheretherketone PEEK Victrex®, polyetheretetoneketone PEEKK or polyetherketoneetheretherketone (PEKEKK Ultrapek®)) can not be stated via lithiation. For the introduction of the sulfinate group, another way must be found for these polymers. It would be desirable to have sulfinated polyetherketones, since these polymer could then be cross-linked The polyetherketones are thermally and mechanically more stable than for example polysulfones or polyphenyleneethers, and therefore cross-linked ionomer membranes from polyetherketone polymers might show better stabilities in (electro)membrane processes.
[0004] From the literature it is known that low-molecular sulfochlorides can be reduced to sulfinates by reduction with Zn dust, iron dust sodium sulfite, hydrazine, H 2 S, LiAlH 4 , triethylaluminium, ethylaluminium sesquichloride. The reduction leads to good yields primarily with Zn dust and with LiAlH 4 . It was surprisingly found now that polymers, which contain non-ionic sulfonate group derivatives, e. g. the sulfochloride group SO 2 Cl, (polymeric sulfochlorides are easily accessibly by reaction of the sulfonic acid group with thionyl chloride, phosphorous trichloride oxide, phosphorous pentoxide or by reaction of lithiated polymers with sulfuryl chloride), can be converted with suitable reducing agents or with mixtures of suitable reducing agents in solution or in suspension in high yield and without cross-linking. The sulfochloride group of the respective polymers can be converted to sulfinate group either completely or partially, depending on type and quantity of reducing agent and or other reaction conditions (e.g. concentration, temperature). The fact that no cross-linking of the polymer as a side reaction takes place during the reduction is primarily remarkable and therefore surprising since it is known for example of sulfinic acids that these can react under disproportionation with each other. It was particularly surprising that the reaction of the polymeric sulfochlorides took place with LiAlH 4 at temperatures of −20 to −60° C. without cross-linking and with a high yield, since at this reaction lewis acidic intermediates appear, which could catalyse the cross-linking of the formed sulfinate group.
[0005] It was further surprising that at the reduction of polymeric sulfochlorides with aqueous sodium salt solutions or other sulphurous reducing agents like sodium dithionite, sodium thiosulfate or mixtures of these reducing agents the reaction can be controlled in such a way, that only a part of the sulfochloride groups is converted to sate groups, and the remaining sulfochloride groups remain unchanged (e. g. are not hydrolyzed to the sulfonic acid group). This is of importance when the sulfinate groups of the polymers containing both sulfochloride and sulfinate groups are alkylated by S-alkylation. Examples of alkylations are:
[0006] covalent crosslinking with dihalogeno or oligohalogeno compounds or other difunctional or oligofunctional alkylation agents or/and
[0007] Reaction with monofunctional alkylation agents.
[0008] The sulfinate S-alkylation apparently proceeds in a greater yield if sulfochloride groups are available in the polymer instead of ionical sulfonic acid salt derivatives. The reason for this is presumably, that unloaded sulfochloride groups are solvated better than sulfonate salt groups by the solvents, which are used normally for polymers containing sulfinate groups (dipolar aprotic solvents like N-methylpyrrolidinone NMP, N,N-dimethylacetamide DMAc, N,N-dimethylformamide DMF, dimethylsulfoxide DMSO or sulfolane). A better solvation leads to a better solubility of both the sulfochlorinated polymer and the sulfinated polymer (ion effect: if the ion concentration and with that the ionic strength of the solution containing the different polymers is smaller, the sulfinated polymer is also dissolved better) and thus to higher reactivity of the polymer (polymers) containing sulfinate groups with the alkylation agents.
[0009] With the method of the present invention a large number of polymeric sulfinates according to the invention becomes accessible—actually every polymer or oligomers sulfonic acid can be transferred after transformation into the sulfohalide or another non-ionic sulfonic acid derivative to the respective polymeric or oligomeric sulfinate. Thus particularly sulfinated polymers become accessible, which can not be sulfinated by other methods, such as e.g. polymers containing carbonyl groups in the main chain or in the side chain. Particularly the high performance thermoplastics from the family of the polyetherketones which can not be lithiated can be sulfinated according to the present invention.
[0010] Thus also new covalent crosslinked oligomers or polymers or polymer(blend)membranes for most different applications become accessible, for example for membrane processes like membrane fuel cells, electrodialysis (if necessary with bipolar membranes), pervaporation, gas separation, diffusion dialysis, reverse osmosis, perstraction etc.
[0011] The special advantage of the reduction process of the present invention consists in that it is possible to reduce the sulfonyl groups only partially by a lower than equimolar amount of reducing agent so that polymer or oligomers which carry both sulfinate and sulfonyl groups on the sane backbone are obtained. The sulfonyl groups can be hydrolyzed acidically, alkaline and/or neutral to the respective sulfonate group in another step, so that an oligomer or polymer which contains both sulfonate and sulfinate group arises, can be converted in a further step to covalently crosslinked proton-conducting polymer membranes, whereby the sulfinate group can be crosslinked according to usual methods.
[0012] Another possibility for the preparation of polymeric sulfohalides, which are only partially reduced to sulfinate is made possible by the use of polymers carrying two or three different sulfohalide groups on the same polymer backbone. Particularly preferred are combinations from sulfochlorides, sulfobromides and/or sulfofluorides. Especially preferred are combinations from sulfochloride and sulfobromide group in the same polymer molecule. The ratios of the sulfohalide groups can be every arbitrary value between each other. Depending on the chosen reducing agent and the solvent used the corresponding sulfohalides show a different tendency towards reduction.
[0013] The preparation of polymers which comprise sulfohalides and sulfate groups on the same backbone is particularly preferred as mentioned above already. Followed by a further processing to a membrane which is covalently crosslinked as it is shown exemplarily in the example 5 with the polymer PEEK. After the crosslinking the remaining sulfohalide group is alternatively hydrolyzed in water, a diluted acid and/or alkaline and transferred into the sulfonic acid or sulfonic acid salt derivative.
[0014] The ratio of sulfochloride to sulfinate group in the end product can accept every arbitrary value. It is only and alone dependent on the chosen reduction conditions. Being included
[0015] a) the duration of the reduction: it is between few seconds up to 60 hours, 10 to 30 hours are preferred
[0016] b) the temperature of the reduction: It is depending on medium between −60° C. and 100° C. Using sodium sulfit as a reducing agent it is between 50° C. and 100° C.
[0017] c) the solvents used: preferred are water and dipolar-aprotic solvents, particularly preferred are dipolar-aprotic polar solvents (as NMP, DMAc, DMSO and THF) and arbitrary mixtures of the solvents with each other.
SUMMARY
[0018] While the reduction of the sulfinated oligomers and polymers according to the invention is carried out, other alkylation agents apart from the di- or oligofunctional crosslinker (for example 1.4 diiodobutane) can be added at the same time to the solution of the sulfinated polymer/oligomer in a suitable solvent, which alkylate sulfinate groups simultaneously with the cross-linking reaction Thereby crosslinked membranes and other formed objects can be produced, whose properties are modified by the additionially introduced functional groups. If the other alkylation agents contain acidic functions, for example, a cation conductivity, particularly a proton conductivity, of the crosslinked membranes and others polymer formed object can be generated. An alkylation with alkylation agents containing basic groups leads to membranes modified with basic anion-exchange groups.
[0019] The main chains (backbones) of the polymers and oligomers of the present invention are arbitrarily chosen, however, the following polymers are preferred, as main chains:
[0020] Polyolefines like polyethylene, polypropylene, polyisobutylene, polynorbornene, Polymethylpentene, polyisoprene, poly(1.4 butadiene), poly(1.2 butadiene)
[0021] Styrene(co)polymer like polystyrene, poly(metylstyrene), poly(α,β,β-triflourostyrene), poly(pentaflourostyrene)
[0022] perflourinated ionomers like Nafion® or the SO2Hal-precursor of Nafion® (Hal=F, Cl, Br, I), Dow® membrane, GoreSelect® membrane
[0023] sulfonated PVDF and/or the SO2Hal-precursor, whereby Hal stands for fluorine, chlorine, bromine or iodine
[0024] (Hetero) aryl main chain polymers like:
Polyetherketones like polyetherketone PEK Victrex®, polyetheretherketone PEEK Victrex®, polyetheretherketoneketone PEEKK, polyetherketoneetherketoneketone PEKEKK Ultrapek® Polyethersulfones like polysulfone Udel®, polyphenylsulfone Radel R®, Polyetherethersulfone Radel A®, polyethersulfone PES Victrex® Poly(benz)imidazole like PBI Celazol® and other oligomers and polymers containing the (Benz)imidazole monomer whereby the (Benz)imidazole group can be present in the main chain or in the polymer lateral chain Polyphenyleneether like e.g. poly(2,6-dimethyloxyphenylene), poly(2,6-diphenyloxyphenylene) Polyphenylenesulfide and copolymeres Poly(1,4-phenylene) or poly(1,3-phenylene), which can be modified in the lateral group, if necessary with benzoyl, naphtoyl or o-phenyloxy-1,4-benzoyl group, m phenyloxy-1,4benzoyl groups or p-phenyloxy-1,4-benzoyl groups. Poly(benzoxazole) and copolymers Poly(benzthiazole) and copolymers Poly(phtalazione) and copolymers Polyaniline and copolymers
DETAILED DESCRIPTION
[0035] The reaction equations (1) and (2) show exemplary the reduction of sulfonated PEEK (polyetheretherketone) to the sulfinate:
[0036] The partial reduction of sulfonated PEEK is exemplarily represented in FIG. 7 over the corresponding sulfochloride to the sulfinate.
[0037] As polymeric sulfinates are very unstable the resulting sodium salt form is transferred into the considerably more stable lithium salt by cation exchange.
[0038] According to the method of the present invention is the partial or complete reduction of sulfochlorinated polysulfone (PSU) or other poly(ethersulfone)s and sulfochlorinated PEEK or other poly(etherketone)s is quite particularly preferred.
[0039] The membranes produced by covalent crosslinking can be applied to hydrogen fuel cells, particularly in membrane fuel cells, in a temperature range of −50° C. to +280° C. depending on the main polymer backbone.
BRIEF DESCRIPTION OF THE DRAWING
[0040] FIG. 1 illustrates an IR spectra of PSU-SO 2 Cl (spectrum 1), of PSU-SO 2 Li produced by reaction of PSU-Li with SO 2 (spectrum 2), and of PSU-SO 2 Li produced by reduction of PSU-SO 2 Cl with LiAlH 2 (spectrum 3).
[0041] FIG. 2 shows on FTIR spectrum of sulfinated PEEK (arrow: Sulfinate bond).
[0042] FIG. 3 shows a comparison of different PEEK sulfoderivatives.
[0043] FIG. 4 illustrates an 1 H-NMR spectrum of the sulfinated PEEK (signals 2, 3, 4 correspond to 6 protons, signal 1 corresponds to 4 protons, 5 corresponds to 1 proton, which yields a sum of 11 protons, 1 proton therefore got substituted).
[0044] FIG. 5 shows an 1H-NMR spectrum of the starting polymer PEEK-SO 2 Cl.
[0045] FIG. 6 illustrates the dependence of the water uptake of the membranes on the temperature.
[0046] FIG. 7 shows the partial reduction of sulfonated PEEK.
[0047] FIG. 8 shows formation of the covalent crosslinked membrane from partially reduced PEEK-SO 2 Cl.
EXAMPLES
[0048] 1. Preparation of a sulfinated polysulfone PSU Udel® by reduction of PSU sulfochloride with lithiumaluminiumhydride 10.83 g sulfochlorinated PSU Udel® are dissolved in 300 ml of tetrahydrofurane (THF). The solution is cooled down under argon protective gas to −65° C. After this 13 ml of a 0.013 molar lithiumaluminiumhydride solution m THF are added within 2 hours via a dropping funnel into the polymer solution. The beginning of the reduction is indicated by hydrogen development. After the hydrogen development is finished, what is the case after about 1 hour, a mixture of 60 ml of 10 per cent LiOH solution and 120 ml ethanol is injected into the reaction rare. After this the reaction mixture is precipitated into 2.5 1 iso-propanol and filtered. The residue is dried at 60° C. in the drying oven at 50 hPascal pressure. The formation of the PSU sulfinate is observed by an IR spectrum of the product. The sulfinate band at 970 cm −1 is considerably recognizable (illus. 1, IR spectra of PSU-SO 2 Cl (spectrum 1) made by reaction of PSU-Li with SO 2 (spectrum 2) of PSU-SO 2 Li and made by reduction of PSU-SO 2 Cl with LiAlH 4 (spectrum 3) of PSU-SO 2 Li.
[0049] 2. Preparation of sulfinated poly(etheretherketone) PEEK by reduction of PEEK-SO 2 Cl with aqueous sodium sulfit solution
[0050] Material:
[0051] 7.6 g PEEK-SO 2 Cl (0.02 mol)
[0052] 126 g of (1 mol) Na 2 SO 3
[0053] 500 ml H2O
PEEK-SO 2 Cl+Na 2 SO 3 +H 2 O→PEEK-SO 2 Na+NaCl+NaHSO 4
[0054] PEEKSO 2 Cl is added to 500 ml of a 2M Na 2 SO 3 solution and is stirred at 70° C. for 20 hours. After this it is heated up to 100° C. and allowed to react for 10 min at this temperature. Then the white polymer is filtered off. The polymer is then stirred in 500 ml of a 10% LiOH solution to transform the sulfinate group into the Li form by ion-exchange. After this it is filtered and the precipitate is washed up to the neutral reaction of the washing water. After this the polymer is dried at room temperature up to weight constancy under vacuum. After this the polymer is suspended in water and dialysed. The dialysed polymer solution is dehydrated and the polymer dried at room temperature and vacuum up to the weight constancy.
[0055] IR: The band of the sulfinate group SO 2 Li is detected easily at 970 cm-1 (illus. 2).
[0056] The sulfinated PEEK is easily soluble in NMP and DMSO. If 1,4-diiodobutane is given to a NMP solution of the polymer, within 5 min a gelation takes place and with that a crosslinking of the polymer. Illus. 4 shows a 1-H-NMR spectrum of the sulfinated PEEK.
[0057] Elemental analysis: 1,0 groups replaced.
C H S Cl Theo. 63.69 3.07 8.94 0 Exp. 52.52 3.71 6.60 1.95
[0058] Elemental analysis after dialysis of the product polymer (there is still Cl present in the polymer as sulfochloride):
C H S Cl Theo. 63.69 3.07 8.94 0 Exp. 53.26 4.09 6.89 2.01
[0059] Elemental analysis of the starting product sulfochlorinated PEEK:
C H S Cl Theo. 59.06 2.85 8.29 9.07 Exp. 57.43 3.07 8.32 9.54
[0060] Elemental analysis with calculated values if 25% of the finctional groups are present as a sulfochloride and 75% of the functional groups as a sulfinate would be:
[0061] Molecular mass 397 g/mol. (C 19 H 11 O 7 S 1 Cl 0.25 Li 0.75 )
C H S Cl Theo. 57.31 2.77 8.06 2.20 Exp. 52.52 3.71 6.60 1.95
[0062] 3. Preparation of partly sulfinated poly(etheretherketone) PEEK by reduction of PEEK-SO 2 Cl with aqueous sodium sulfite solution
[0063] Material:
[0064] 20 g PEEK-SO 2 Cl (0.053 mol)
[0065] 300 ml of 2 molar aqueous solutions of Na 2 SO 3
PEEK-SO 2 Cl+Na 2 SO 3 +H 2 O→PEEK SO 2 Na+NaCl+NaHSO 4
[0066] PEEKSO 2 Cl is added to 300 ml of a 2M Na 2 SO 3 solution and is stirred at 70° C. for 20 hours. Then the white polymer is filtered off. The polymer is then stirred in 500 ml of a 10% LiOH solution to bring the sulfinate group in the Li form. After this it is filtered and the precipitate is washed up to the neutral reaction of the washing water. After this the polymer is dried at room temperature up to weight constancy under vacuum. After this the polymer is suspended in water and dialysed. The dialysed polymer solution is dehydrated and the polymer dried at room temperature and vacuum up to weight constancy.
[0067] Elemental analysis results after dialysis:
C H S Cl Theo. 63.69 3.07 8.94 0 Exp. 56.21 4.00 6.75 2.55
[0068] The elemental analysis result corresponds to about 0.28 remaining sulfochloride group and 0.72 obtained sulfinate group per repeating unit. A redox titration of the sulfinated polymer with a surplus of NaOCl and back titration with sodium thiosulfate yields about 0.58 sulfinate group per repeating unit.
[0069] Data of the titration:
[0070] C Na2S2O3 =0.1N
[0071] C NaOCl =0.4962 mmol/g
[0072] 1.259 g PEEK-SO 2 Li
[0073] 11,265 g NaOCl(5,5897 mmol)
[0074] V Na2S2O3 =70,626 ml
[0075] G NaOCl =70,626*0,1/2=3,5313 mmol
[0076] G SO2Li =5,5897−3,5313=2,0584 mmol
[0077] 40° C., 4 Stunden. 150 ml H 2 O.
[0078] IEC PEEK-SO2Li =2,0584/1,259=1.63 mmol/g (approximately 0.58 SO 2 Li groups per repeating unit).
[0079] The oxidized polymer is titrated with 0.1 N NaOH. It results an IEC of 2.52 meq SO 3 H groups per g of polymers. The starting polymer sulfonated PEEK (before sulfochloride formation) had an IEC of 2.7 meq/g.
[0080] 4. Production of partially reduced PEEK-SO 2 Cl
[0081] Material:
[0082] 7.6 g PEEK-SO 2 Cl (0.02 mol)
[0083] 126 g of (1 mol) Na 2 SO 3
[0084] 500 ml H 2 O
PEEK-SO 2 Cl+Na 2 SO 3 +H 2 O→ClO 2 S-PEEK-SO 2 Na+NaCl+NaHSO 4
[0085] PEEKSO 2 Cl is added to 300 ml of a 2M Na 2 SO 3 solution and is stirred at 70° C. for 20 hours. Then the white polymer is filtered off. The polymer is then stirred in 500 ml of a 10% LiOH solution to bring the sulfinate group in the Li form. After this it is filtered and the precipitate is washed up to the neutral reaction of the washing water. After this the polymer is dried at room temperature up to weight constancy under vacuum. After this the polymer is suspended in water and dialysed. The dialysed polymer solution is dehydrated and the polymer dried at room temperature and vacuum up to the weight constancy. The obtained product contains both sulfinate and sulfochloride groups.
[0086] 5. Preparation of covalently crosslinked membranes by using sulfinated PEEK
[0087] The sulfinated PEEK from example 3 (0.72 sulfinate group and 0.28 sulfochloride group per repeating unit) is dissolved, if necessary together with sulfonated PEK-SO 3 Li (for IEC sPEK =1.8 meq/g), in NMP to give a 15% solution. The crosslinker 1,4-diiodobutane is added to the solution, and a membrane is cast. The solvent is evaporated in the vacuum drying oven (first 100° C./800 hPas, then 120° C./50 hPas), and the membrane taken out of the drying oven. After cooling, it is removed under water, posttreated in 7% NaOH at 60° C. for 1 day, followed by water at 90° C. for 1 day, ten in 10% H 2 SO 4 at 90° C. for 1 day, and finally in water at 90° C. for 1 day.
[0088] Membrane preparation:
Membrane Sulfinated Sulfonated 1,4-diiodobutane [no.] PEEK [g]* PEK [g]** NMP [g] [ml] PEEK 1 1 2 20 0.23 PEEK 2 1 1 20 0.24 PEEK 3 1 — 10 0.1 *Sulfinated PEEK from example 3 **1.8 = meq SO 3 Li/g of polymers sulfonated PEEK with IEC
[0089] Characterization results of the membranes:
Membrane IECexp. IECtheo Water Rsp Extraction [no.] [meq/g] [meq/g] uptake [%] [Ω * cm]* residue [%]** PEEK-1 1.61 1.53 76.2 4.2 — PEEK-2 1.4 1.4 85.9 5.13 39.4 PEEK-3 1.01 1.0 18.1 22.1 100 *measured in 0.5 N HCl, impedance at room temperature (25° C.) **stored in 90° C. hot DMAc, residue centrifuged off, washed with MeOH and water and dried in vacuum at increased temperature
[0090] One sees from illus. 6, that the swelling of the covalently crosslinked membrane from PEEK-SO 2 LiSO 2 Cl (PEEK which contains both sulfochloride and sulfinate group) is even at a temperature of 90° C. only 33%, and this at a high proton conductivity of 22.1 Ω*cm. This is a remarkable result which lets expect for this membrane very good prospects at the application into membrane fuel cells at T>80° C.
[0091] Following in the scheme the formation of the covalent crosslinked membrane from partially reduced PEEK-SO 2 Cl: FIG. 8
[0092] The polymers particularly preferred in the context of the invention are shown with their structures on the following pages once again. The shown polymers are substituted with sulfohalide groups prior to the reduction. The substitution degree per recurring unit is different from polymer to polymer and can reach values up to 10 sulfohalide groups per repeating unit. Values of 1 to 5, particularly of 2 to 4 sulfohalide groups are preferred. 100% of the sulfohalide groups can be reduced to sulfinate groups, however, a partial reduction of the sulfohalide groups to sulfinate groups is preferred. A value of 30 to 60% of the used sulfohalide groups is preferred.
[0093] For the preparation of covalent membranes from polymers that carry both sulfohalide and sulfochloride groups, membranes are preferred, that have an ion exchange capacity (IEC) of 0.8 to 2.2 after the hydrolysis, membranes with an IEC from 1.0 to 1.8 are particularly preferred.
[0094] The polymers with repeating units of the general formula (1) that are particularly preferred in the context of the present invention include homopolymers and copolymers, examples being random copolymers, such as ®Victrex 720 P and ®Astrel. Especially preferred polymers are polyaryl ethers, polyaryl thioethers, polysulfones, polyether ketones, polypyrroles, polythiophenes, polyazoles, phenylenes, polyphenylenevinylenes, polyanilines, polyazulenes, polycarbazoles, polypyrenes, polyindophenines and polyvinylpyridines, especially polyaryl ethers:
[0095] Polyarylethers:
[0096] In the context of the present invention, n designates the number of repeating units along one macromolecule chain of the crosslinked polymer. This number of the repeating units of the general formula (1) along one macromolecule chain of the crosslinked polymer is preferably an integer greater than or equal to 10, in particular greater than or equal to 100. The number of repeating units of the general formula (1A), (1B), (1C), (1D), (1E), (1F), (1G), (1H), (1I), (1J), (1K), (1L), (1M), (1N), (1O), (1P), (1Q), (1R), (1S) and/or (1T) along one macromolecule chain of the crosslinked polymer is preferably an integer greater than or equal to 10, in particular greater than or equal to 100.
[0097] In one particularly preferred embodiment of the present invention, the numerical average of the molecular weight of the macromolecule chain is greater than 25,000 g/mol, appropriately greater than 50,000 g/mol, in particular greater than 100,000 g/mol.
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The invention relates to novel polymers or oligomers containing at least sulfonite groups (P—(SO 2 ) n X, X=1−(n=1), 2−(n=2) or 3−(n=3) valent metal cation or H + or ammonium ion NR 4 + where R=alkyl, aryl, H), which are obtained by completely or partially reducing polymers or oligomers containing at least SO 2 Y-groups (Y═F, Cl, Br, I, OR, NR 2 (R=alkyl and/or aryl and/or H), N-imidazolyl, N-pyrazolyl) by means of suitable reducing agents in a suspension or in a solution form. The invention also relates to polymers and polymer(blend) membranes which are obtained by further reacting the obtained sulfinated polymers, especially by alkylation of the sulfinate groups with mono- di- or oligo functional electrophiles. The invention further relates to methods for producing the sulfinated polymers and for further reacting the sulfinated polymers with electrophiles by S-alkylation.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for forming a fibrous web wherein a polymer stream is spun through a spinning nozzle into an electric field of sufficient strength to impart electrical charge on the polymer and wherein a forwarding gas stream aids in transporting the polymer away from the spinning nozzle.
BACKGROUND OF THE INVENTION
[0002] PCT publication no. WO 03/080905A discloses an apparatus and method for producing a nanofiber web. The method comprises feeding a polymeric solution to a spinning nozzle to which a high voltage is applied while compressed gas is used to envelop the polymer solution in a forwarding gas stream as it exits the nozzle, and collecting the resulting nanofiber web on a grounded suction collector.
[0003] There are several disadvantages to the process disclosed in PCT publication no. WO 03/080905A, particularly if the process is carried out on a commercial scale. For one, the spinning nozzle, and the spinneret and spin pack of which the nozzle is a component and all of the associated upstream solution equipment is maintained at high voltage during the spinning process. Because the polymer solution is conductive, all of the equipment in contact with the polymeric solution is brought to high voltage, and if the motor and gear box driving the polymeric solution pump are not electrically isolated from the pump, a short circuit will be created which will reduce the voltage potential of the pack to a level insufficient to create the electric fields required to impart charge on the polymer solution.
[0004] Another disadvantage of the process disclosed in PCT publication no. WO 03/080905A is that the process solution and/or solvent supply must be physically interrupted in order to isolate it from the high voltage of the process. Otherwise, the solution and/or solvent supply systems would ground out the pack and eliminate the high electric fields required for imparting charge on the polymeric solution.
[0005] Additionally, all of the equipment in contact with the electrified polymer solution must be electrically insulated for proper and safe operation. This insulation requirement is extremely difficult to fulfill as this includes large equipment such as spin packs, transfer lines, metering pumps, solution storage tanks, pumps, as well as control equipment and instrumentation such as pressure and temperature gauges. A further complication is that it is cumbersome to design instrumentation and process variable communication systems which can operate at high voltages relative to ground. Furthermore, all exposed sharp angles or corners that are held at high voltage must be rounded, otherwise they will create intense electric fields at those points which may discharge. Potential sources of sharp angles/corners include bolts, angle irons, etc. Moreover, the high voltage introduces a hazard to those persons providing routine maintenance to electrified equipment in support of an on-going manufacturing process. The polymeric solutions and solvents being processed are often flammable, creating a further potential danger exacerbated by the presence of the high voltage.
SUMMARY OF THE INVENTION
[0006] The invention relates to an electroblowing process for forming a fibrous web comprising:
[0007] (a) issuing a polymer stream from a spinning nozzle in a spinneret whereupon a fibrous web is formed, the web having an electric charge of a positive or negative polarity, and
[0008] (b) collecting the fibrous web on a collection means,
[0009] wherein a voltage is applied to the collection means, the voltage having a polarity opposite that of the fibrous web, and wherein the spinneret is substantially grounded, such that an electric field is generated between the spinneret and the collection means of sufficient strength to impart an electrical charge on the polymer stream as it issues from the spinning nozzle.
DEFINITIONS
[0010] The terms “electroblowing” and “electro-blown spinning” herein refer interchangeably to a process for forming a fibrous web by which a forwarding gas stream is directed generally towards a collection means, into which gas stream a polymer stream is injected from a spinning nozzle, thereby forming a fibrous web which is collected on the collection means, wherein a voltage differential is maintained between the spinning nozzle and the collection means and the voltage differential is of sufficient strength to impart charge on the polymer as it issues from the spinning nozzle.
[0011] The term “nanofibers” refers to fibers having diameters of less than 1,000 nanometers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate the presently contemplated embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0013] FIG. 1 is an illustration of the prior art.
[0014] FIG. 2 is a schematic of a process according to the present invention.
[0015] FIG. 3A is a schematic of an alternative process according to the present invention.
[0016] FIG. 3B is a detail from FIG. 3A of the collection means.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the drawings, like reference characters are used to designate like elements.
[0018] An electroblowing process for forming fibrous web is disclosed in PCT publication number WO 03/080905A ( FIG. 1 ), the contents of which are hereby incorporated by reference. There are several disadvantages to this process, as already described herein in the Background of the Invention.
[0019] It would be desirable to have an improved electroblowing process which would avoid these disadvantages.
[0020] In the process of the present invention, referring to FIG. 2 , according to one embodiment of the invention, a polymer stream comprising a polymer and a solvent, or a polymer melt, is fed from a storage tank, or in the case of a polymer melt from an extruder 100 to a spinning nozzle 104 (also referred to as a “die”) located in a spinneret 102 through which the polymer stream is discharged. Compressed gas, which may optionally be heated or cooled in a gas temperature controller 108 , is issued from gas nozzles 106 disposed adjacent to or peripherally to the spinning nozzle 104 . The gas is directed generally downward in a forwarding gas stream which forwards the newly issued polymer stream and aids in the formation of the fibrous web.
[0021] While not wishing to be bound by theory, it is believed that the forwarding gas stream provides the majority of the forwarding forces in the initial stages of drawing of the fibers from the issued polymer stream and in the case of polymer solution, simultaneously strips away the mass boundary layer along the individual fiber surface thereby greatly increasing the diffusion rate of solvent from the polymeric solution in the form of gas during the formation of the fibrous web.
[0022] At some point, the local electric field around individual fibers is of sufficient strength that the electrical force becomes the dominant drawing force which ultimately draws the individual fibers to diameters measured in the hundreds of nanometers or less.
[0023] It is believed that the geometry of the tip of the spinning nozzle, also referred to as the “die tip,” creates an intense electric field in the three-dimensional space surrounding the tip which causes charge to be imparted to the web. The die tip may be in the form of a cylindrical capillary or in the form of a linear array of cylindrical capillaries. In the embodiment in which the die tip is a linear array, the forwarding gas stream is issued from gas nozzles 106 on each side of the spinneret 102 . The gas nozzles are in the form of slots formed between elongated knife edges, one on each side of the spinneret, along the length of the linear array, and the spinneret. Alternately, in the embodiment in which the die tip is in the form of a cylindrical capillary, the gas nozzle 106 may be in the form of a circumferential slot surrounding the spinneret 102 . It is believed that the electric field combined with the charge on the fibrous web provides spreading forces which act on the fibers and fibrils of the web, causing the web to be better dispersed and providing for very uniform web laydown on the collection surface of the collection means.
[0024] The velocity of the compressed gas issued from gas nozzles 106 is advantageously between about 10 m/min and about 20,000 m/min, and more advantageously between about 100 and about 3000 m/min.
[0025] Advantageously, the polymeric solution is electrically conductive. Examples of polymers for use in the invention may include polyimide, nylon, polyaramide, polybenzimidazole, polyetherimide, polyacrylonitrile, PET (polyethylene terephthalate), polypropylene, polyaniline, polyethylene oxide, PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), SBR (styrene butadiene rubber), polystyrene, PVC (polyvinyl chloride), polyvinyl alcohol, PVDF (polyvinylidene fluoride), polyvinyl butylene and copolymer or derivative compound thereof. The polymer solution is prepared by selecting a solvent suitable to dissolve the polymer. The polymer solution can be mixed with additives including any resin compatible with an associated polymer, plasticizer, ultraviolet ray stabilizer, crosslink agent, curing agent, reaction initiator, etc. Any polymer solution known to be suitable for use in a conventional electrospinning process may be used in the process of the invention.
[0026] In another embodiment of the invention, the polymer stream fed to the spin pack and discharged through the nozzle in the spinneret is a polymer melt. Any polymer known to be suitable for use in a melt spinning process may be used in the process in the form of a polymer melt.
[0027] Polymer melts and polymer-solvent combinations suitable for use in the process are disclosed in Z. M. Huang et al., Composites Science and Technology, volume 63 (2003), pages 2226-2230, which is herein incorporated by reference.
[0028] Located a distance below the spinneret 102 is a collection means for collecting the fibrous web produced. In one embodiment of the invention, as shown in FIG. 2 , the collection means comprises a moving conductive belt 110 connected to high voltage onto which the fibrous web is collected. The belt 110 is advantageously made from a porous conductive material such as a metal screen so that a vacuum can be drawn from beneath the belt through gas collecting tube 114 by blower 112 . In this embodiment of the invention, the collection belt must be isolated from ground by any known means. The collected fibrous web of nanofibers is sent to a wind-up roll, not shown.
[0029] In another embodiment of the invention, as shown in FIGS. 3A and 3B , the moving collection substrate 118 ( FIG. 3B ) is a nonconductive substrate superposed over a conductive element 120 connected to high voltage, itself superposed on a nonconductive support material 122 . The conductive element 120 and/or the nonconductive support material 122 can be stationary. The moving collection substrate 118 is supplied from a supply roll 124 and the combined collected fibrous nanofiber web and collection substrate 118 are sent to a wind-up roll 126 . In one embodiment of the invention, nanofibers and the forwarding gas stream are directed toward the collection substrate 118 , where the nanofibers are deposited and collected into a fibrous nanofiber web superposed on the nonconductive collection substrate 118 . The collection substrate 118 , conductive element 120 and support material 122 are each highly breathable, so that the gas from the forwarding gas stream as it impinges the collection substrate may be exhausted through the collection substrate 118 , conductive element 120 and support material 122 using vacuum. The vacuum can be drawn from beneath the support material 122 through gas collecting tube 114 by blower 112 . The collection substrate 118 can be any of a number of substantially nonconductive breathable materials such as woven fabrics, nonwoven fabrics, scrims, etc. When the forwarding gas stream gases are exhausted by vacuum, the conductive element 120 is a porous material, and more advantageously a metal screen, for example a fine mesh screen having a mesh greater than about 50 . In this embodiment, the high voltage conductive screen 120 must be isolated from ground by any known means.
[0030] In another embodiment, a nonconductive moving collection substrate 118 according to FIG. 3B can be supplied from a supply roll and fed over the moving conductive belt 110 of FIG. 2 . In this manner, a fibrous web containing nanofibers is deposited onto the collection substrate, the combination of nanofiber web and nonconductive moving collection substrate are separated from the moving conductive belt by conventional means and are forwarded to a wind-up roll.
[0031] It has been found that the distance between the spinneret and the collection surface (also referred to as the “die to collector distance” or “DCD”; illustrated in FIGS. 2 and 3 A) is in the range of about 1 to about 200 cm, and more advantageously in the range of about 10 to about 50 cm.
[0032] It has further been found that when the tip of the spinning nozzle or die tip protrudes from the spinneret by a distance e ( FIGS. 2 and 3 A), such that the distance between the nozzle and the collection surface is less than the distance between the spinneret and the collection surface, a more uniform electric field results. Not wishing to be bound by theory, it is believed that this is because the protruding nozzle establishes a sharp edge or point in space for electric field lines to concentrate around.
[0033] The voltage applied to the collection means, either to the moving conductive belt 110 as in FIG. 2 or the stationary conductive screen 120 as in FIG. 3 , is in the range of about 1 to about 500 kV, and more advantageously about 10 to about 100 kV.
[0034] The process of the invention avoids the necessity of maintaining the spin pack including the spinneret, as well as all other upstream equipment, at high voltage, as described in the Background of the Invention. By applying the voltage to the collection means, the pack, the spinneret and all upstream equipment may be grounded or substantially grounded. By “substantially grounded” is meant that the spinneret may be held at a low voltage level, i.e., between −100 V and +100 V.
[0035] Advantageously, the polymer discharge pressure is in the range of about 0.01 kg/cm 2 to about 200 kg/cm 2 , more advantageously in the range of about 0.1 kg/cm 2 to about 20 kg/cm 2 , and the polymer solution throughput per hole is in the range of about 0.1 cc/min to about 15 cc/min.
EXAMPLE 1
[0036] A test was run with a 0.1 meter spin pack to demonstrate the process while applying high voltage to the collector. In this test, the collector consisted of a rectangular metal screen supported by a frame. The collector was stationary and electrically insulated from ground with the use of Teflon® supports. A voltage of −60 kV was applied to the collector and the spin pack was connected to ground.
[0037] A 22 wt % solution of nylon 6 (type BS400N obtained from BASF Corporation, Mount Olive, N.J.) in formic acid (obtained from Kemira Industrial Chemicals, Helsinki, Finland) was electroblown through a spinneret of 100 mm wide, having 11 nozzles at a throughput rate of 1.5 cc/hole. A forwarding air stream was introduced through air nozzles at a flow rate of 4 scfm (2 liters per second). The air was heated to about 70° C. The distance from the spinneret to the upper surface of the collector was approximately 300 mm. The process ran for about 1 minute.
[0038] Nineteen fibers from the product collected were measured for fiber diameter. The average fiber size was 390 nm with a standard deviation of 85.
COMPARATIVE EXAMPLE
[0039] The test was repeated as described above with the negative voltage supply attached to the spin pack. All other process settings were the same.
[0040] The process ran equally well as the process in tests conducted in which the high voltage was applied to the spin pack and the collection surface was grounded. Fine fibers were produced which pinned well to the collector.
[0041] Nineteen fibers from the product collected were measured for fiber diameter. The average fiber size of the Comparative Example was 511 nm with a standard deviation of 115.
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An improved electroblowing process is provided for forming a fibrous web of nanofibers wherein polymer stream is issued from a spinning nozzle in a spinneret with the aid of a forwarding gas stream and a resulting nanofiber web is collected on a collection means. The process includes applying a high voltage to the collection means and grounding the spinneret such that an electric field is generated between the spinneret and the collection means of sufficient strength to impart an electrical charge on the polymer as it issues from the spinning nozzle.
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BACKGROUND OF THE INVENTION
This invention relates generally to mechanical face seals for sealing the space between a rotating shaft and its housing and in particular to face seals having grooves in their sealing surfaces for maintaining a gap between the relatively rotating sealing members.
Spiral groove mechanical face seals are used to create a non-contacting seal between a rotating shaft and its housing. A gap between two sealing faces, one of which is rotating with regard to the other, is maintained by a film of pressurized fluid pumped between the faces by spiral grooves in at least one of the sealing faces. Examples of spiral groove face seals are found in U.S. Pat. No. 3,804,424 issued to Gardner and U.S. Pat. Nos. 4,212,475 and 4,290,611 issued to Sedy. All of these patents are commonly assigned to the assignee of the present invention.
The spiral groove face seals described in these patents and generally those in present use include an annular primary sealing ring having a radially extending face in sealing relation with the radially extending face of an annular mating ring. In operation, either the primary ring or the mating ring rotates with the shaft and includes a radial face in sealing relation to the radial face of the other ring which is itself sealed against the housing. In conventional contacting seals, friction between the two faces during relative rotation produces heat, causing seal face deformation, accelerated aging of the seal components and other undesirable conditions.
It has been found that a very narrow gap or space between the radial faces permits some of the sealed fluid to leak or flow to the low pressure side and that the fluid flow prevents unwanted heat generation. Such a gap is obtained by a series of spiral grooves in the face of either the primary or mating ring which, upon rotation of one of the rings, act as a pump to force fluid between the seal faces. The fluid flow separates the faces and acts as a lubricant, maintaining the gap and allowing the faces to slide against one another without contact between them.
Other mechanical face seals utilizing grooved surfaces have been proposed. For example, U.S. Pat. No. 4,420,162 describes a face seal having spiral grooves extending from the inner circumference to the outer circumference that are both forwardly and rearwardly inclined with respect to the direction of rotation of the seal face. One set of either forwardly or rearwardly inclined grooves acts to pump the sealed fluid out of the gap between seal faces while the oppositely inclined set of grooves acts to pump fluid into the gap.
These seal face designs, however, do not provide the ideal sealing structure. The seal face spiral groove structure described in U.S. Pat. No. 4,420,162 pumps fluid through the seal in a contacting seal face environment.
Seal faces pumping fluid in only one direction provide a fluid film thickness between the faces that is excessive and results in unwanted and unnecessary leakage. The leakage is somewhat reduced if there is a sealing dam adjacent either the inner or outer diameter of a sealing ring. A dam is an ungrooved annular surface adjacent to the grooved annular surface Moreover, the asymmetry in the spiral direction of the prior art seal faces permit their rotation in only one direction so as to produce their intended gap creating function. Rotation of the shaft in the opposite direction or improper installation of the sealing rings creates a vacuum instead of a gap, and operation of the equipment can seriously damage one or both of the seal faces.
As is recognized by Sedy in U.S. Pat. No. 4,212,475, it is desirable to make the fluid film thickness as small as possible to reduce leakage while simultaneously increasing the film stiffness and thus providing stability to the seal faces and gap dimension. The solution proposed by Sedy provides for specific parameters in the length, width and thickness of the grooves relative to the dimensions of the lands and the dam. This solution works well enough when fluid leakage is not a problem, but will nevertheless produce more excess leakage than is necessary.
SUMMARY OF THE INVENTION
One object of the present invention is to provide for a raised pattern configuration on a seal face which minimizes fluid leakage through the gap between the faces of a mechanical face seal.
Another object of the present invention is to provide a raised pattern configuration capable of providing a gap between the sealing faces of a mechanical end face seal without reference to the direction of rotation of the shaft and rotating ring.
Another object of the present invention is to provide a raised pattern configuration which is capable of providing a thin fluid film having a high stiffness without requiring external liquid lubrication.
Still another object of the present invention is to provide a non-contacting non-wearing seal which pumps fluid across the sealing faces and which provides for a thin fluid film gap and for minimal fluid leakage.
Another object and an important feature of the present invention is a static and a dynamic mechanical face seal which provides a minimum of leakage of fluid across the sealing faces under both static and dynamic conditions.
Accordingly, there is provided in a mechanical face seal, a sealing face in at least one of either the primary or mating rings, the sealing face including a raised pattern portion having discontinuous grooves extending inwardly from one circumference of the face, where the discontinuities are defined by a series of raised surfaces extending around the periphery of the grooved portions and forming narrow dams, known as microdams, so that each discontinuous groove is comprised of a plurality of grooved polygonal surfaces disposed in the face of a ring adjacent to each other and separated by microdams. The discontinuous grooves may be either rearwardly directed, relative to the intended shaft rotation, or may be both rearwardly and forwardly directed to provide for bi-directional rotation of the shaft.
Also disclosed is a series of circumferentially disposed entrance lands defined by having one edge of each entrance land coinciding with the circumferential edge of the circumference of the seal ring face, a radially extending edge of each entrance land being forwardly inclined and another radially extending edge being rearwardly inclined relative to the direction of rotation of the seal ring. The forwardly and rearwardly inclined edges each define an intersecting angle with the circumferential edge of said seal ring relative to a tangent, each intersecting angle being of from about 10 degrees to about 30 degrees. The interesecting angle of each radially extending edge, which is forwardly inclined relative to the rotation of the shaft of each entrance land provides an entrance effect to said seal ring face upon shaft rotation in either direction.
Alternatively or in conjunction, polygonal land areas are disposed between successive discontinuous grooves, the lands providing a fluid barrier to egress of the fluid which is impelled inwardly from the circumference of the seal face by the entrance effect of the entrance lands or the microdam surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view in section of a mechanical face seal used in accordance with the present invention;
FIG. 2 is an end view of a sealing ring having a conventional spiral groove pattern;
FIG. 3 is an end view of a sealing ring having a raised patter configuration according to the present invention;
FIG. 4 is a cross-sectional view of the sealing ring illustrated in FIG. 3 taken along a line approximately at IV--IV;
FIG. 5 is an end view of an alternate embodiment of sealing ring having a raised pattern configuration according to the present invention;
FIG. 6A is an expanded cross-sectional view of the sealing ring embodiment illustrated in FIG. 5 taken along a line approximately at VI--VI; and
FIG. 6B is an approximate plot of the pressure profile of the raised pattern of FIG. 6A following approximately similar dimensions along the X-axis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The environment in which the present invention will be used is depicted in FIG. 1. This environment includes the housing 10 of a compressor (not shown) and a rotating shaft 12 extending through the housing.
The mechanical face seal according to the present invention is used to seal high pressure within the space 14 against leakage to the atmosphere A.
The basic components of the invention include an annular primary sealing ring 20 having a radially extending face 22 in sealing relation with the radially extending face 24 of an annular mating ring 26.
Details of the structure and operation will be discussed as they relate to the present invention, and reference to U.S. Pat. No 4,212,475 is recommended for further discussion of mechanical groove seals in general.
In operation, the mating ring 26 rotates with the shaft with its radial face 24 being in sealing relation to the radial face 22 of primary ring 20. Friction between these faces upon relative rotation produces heat. To avoid undue heat generation, the seal operates as a gap type seal, e.g. with a very narrow gap or space between the radial faces 22 and 24 to permit leakage or flow from the space to the lower pressure side.
Referring now to FIG. 2, an end view of the sealing face of a conventional ring is illustrated. The particular elements shown in FIG. 2 provide a means for maintaining a gap between the sealing faces of the rings 20 and 26. As is well known in the art, this gap is obtained by forming grooves 70 in the face of either the primary or mating ring. Upon rotation, these grooves act as a pump to force fluid into the gap between the seal faces. The fluid separates the faces to permit the desired leakage. Many of the groove patterns presently used have a spiral design and the seals are therefore known as spiral groove mechanical face seals. The general design considerations for a conventional spiral groove gap type seal are well known.
The stability of the seal faces depends to a great degree in maintaining a parallel relation between the seal faces relative to each other, as is described in U.S. Pat. No. 4,212,475. Seal stability is in part related to the stiffness of the fluid film between the faces. In the case of spiral groove seals, the stiffness and, therefore, stability increase with decreasing fluid film thickness. It is, therefore, desirable to make film thickness as small as possible. This can be done simply by increasing the seal balance. However, pressure and temperature deflections distort the planar quality of the sealing faces and increase the danger of face contact, face damage, and possible seal destruction. Following the teaching of the present invention, these pressure and temperature deflections are minimized by the unique pattern design of a seal face which is capable of maintaining a very thin but highly stable fluid film thickness which nevertheless maintains the parallelity of the sealing faces.
In the conventional embodiment described in U.S. Pat. No. 4,212,475, a self-aligning feature of that invention obtained parallelity of the seal faces by the dimensioning of three seal parameters within specified ranges. These parameters are (1) depth of the grooves; (2) seal balance; and (3) dam width. For a complete description of the optimum ranges of these parameters, reference to U.S. Pat. No. 4,212,475 is once again recommended.
The three parameters described in detail in U.S. Pat. No. 4,212,475 are not exhaustive of the elements and parameters which affect the seal gap, seal gap thickness and seal gap stability. There are approximately 70 parameters which affect the function of a mechanical face seal, and modification of any one of them will necessarily cause a change in the operation of the seal and seal gap. The present invention is directed to a modification of the grooves in the sealing face of one of the rings which provides narrower and more stable seal gaps while yet at the same time maintaining the separation between the sealing faces and preventing contact between them.
Referring now to FIGS. 3 and 4, there is illustrated a sealing ring 76 including a sealing face 78 utilizing the teachings of the present invention. Like the prior art sealing face 24 shown in FIG. 2, sealing face 78 comprises a groove portion 80 and a dam portion 82. The dam portion 82 is substantially the same as the dam portion shown in FIG. 2, and is bounded by a circle having a diameter GD defining the boundary between the groove portion 80 and the dam portion 82.
The groove portion 80, however, has several differences in relation to the groove portion of ring 26. These differences are significant features of the present invention and directly provide the advantages mentioned above.
One significant difference is that ring 26 provides grooves 70 which are asymmetrical relative to the circumferential direction of the sealing face. That is, groove portion 80 of seal ring 76 includes a set of forwardly directed grooves 84 as well as a set of rearwardly directed grooves 86, each separated by land areas 88. The two sets of grooves 84,86 intersect at discrete polygons 90 which define areas of the surface of groove portion 80, and each of the polygons 90 comprising these areas of intersection are bounded by microdams 92.
The microdams 92 can be any width commensurate with the requirement that each groove be capable of maintaining a fluid interface between the faces of the seal rings. A preferred width of the microdams 92 is approximately 0.025 inches for a seal adapted for use with a shaft having a diameter of 4 inches. The height of the microdams 92 relative to the race of seal ring 76 is preferably the same height as the dam portion 82 and the land areas 88, as is shown in FIG. 4. All the ungrooved surfaces, i.e. the dam portion 82, the land areas 88 and the microdams 92 are in the same plane.
The seal pattern illustrated in FIG. 3 shows a spiral groove pattern on the seal face, but other groove path patterns are also contemplated for use with this invention. For example, the grooves may be straight and disposed tangentially to the inner diameter circumference. Alternatively, the grooves may be disposed at various angles relative to the inner diameter circumference or different grooves may be disposed in a combination of angles.
Another preferred embodiment of the present invention is a seal face pattern which provides a surface with microdams in substantially the same plane and which further have only grooved surfaces between the microdam surfaces. FIG. 5 illustrates a ring 76' having a seal face pattern according to this embodiment where the groove portion 80' comprises a substantially greater radial dimension than the dam portion 82' than does the corresponding dimensions 80,82 of the embodiment illustrated in FIG. 3. This difference in relative radial dimension translates into a surface area of the annular grooved portion 80' which is significantly greater than the surface area of the annular dam portion 82'.
Another major difference from the embodiment of FIG. 3 is that the pattern of the embodiment of FIG. 5 lacks land areas, such as the land areas 88 illustrated in FIGS. 3 and 4. The surface of the groove portion 80' is effectively a lacework pattern of forwardly and rearwardly inclined spiral microdams 96 on a planar grooved surface. The spiral microdams 96 define polygonal surfaces such as the four-sided polygons 94, shaped substantially like diamonds, and three-sided polygons 98, shaped substantially like triangles. These surfaces are depressed or grooved areas which are below the plane of the microdam surfaces. The grooved polygonal surfaces 94 and 98 are at a depth of approximately 200-400 microinches, which is deeper than the groove depth of conventional grooves 70 of the ring 26 shown in FIG. 2. The depth of the various surfaces 94,98 may be uniform, but uniformity of the grooved surfaces is not necessary.
Another feature of the embodiment shown in FIG. 5 is the three-sided polygonal surfaces 98 at the edge of the seal face. These surfaces are defined by microdams 96 that form an oblique angle with the edge of the surface. It has been determined that if these surfaces 98 are not grooved but are in the same plane as the surface of the microdams 96 surfaces, then rotation of the ring in either the clockwise or the counterclockwise directions provides a greater capability of the ring to pump fluid from the edge of the ring where these surfaces are disposed toward the center of the annular grooved portion 80'. The pumped fluid then maintains an adequate stiffness and thickness to maintain the proper gap between the seal faces. Moreover, the microdam structure and polygonal four-sided surfaces 94 maintain a sealing capability which substantially reduces fluid leakage through the gap between the seal faces.
The width of the microdam 96 measured at the planar surface can be in a range of from about 0.001 to about 0.100 inches, with the preferable width being about 0.025 inches. As is discussed above, the grooved surfaces are at a depth of between about 50 to about 800 microinches with the preferable depth being approximately 350 microinches.
In a preferred embodiment, the ring material is tungsten carbide and the ring 76' is used as the rotating, mating ring, similar to ring 26 of the seal shown in cross section in FIG. 1 The grooved surfaces are produced by methods known to those skilled in the art.
FIG. 6A is an expanded cross-sectional view of the sealing ring 76' of FIG. 5. The cross-sectional view of FIG. 6A is expanded to provide a relative approximate plot of the pressure profile illustrated in FIG. 6B. FIGS. 6A and 6B are positioned one above the other so that there is a correspondence along the ordinate (X-axis) between the pressure profile of FIG. 6B and the radial position as taken from the inner diameter (I.D.) to the outer diameter (O.D.) of the ring shown in FIG. 5. It is to be understood that the pressure profile of FIG. 6B is only illustrative of the physical model of the ring 76' when in use. Because the separate polygonal grooved surfaces 94 are three-dimensional, it is not possible to represent in simple form the pressure profile of the grooved surface 94. Thus, the pressure profile of FIG. 6B is only an approximate rendering of a hypothetical cross-sectional slice taken through the ring 76'.
The pressure profile of FIG. 6B illustrates the relative pressures hypothetically taken at points along the surface of the ring 76'. The pressure at the inner diameter (I.D.) is atmosphere pressure, and is indicated by P ATM . The pressure at the outer diameter (O.D.) is at the sealed pressure and is indicated by P OD .
As in all conventional gap type seals, the fluid being sealed, located at the O.D. in this illustrative embodiment, leaks through the gap and over the surface of the ring from the high pressure, here the O.D., side toward the atmospheric (P ATM ) pressure, which is at the I.D. The fluid at the O.D. is impelled inwardly by the raised triangular ungrooved surfaces 98, in an entrance effect created by pumping action. Reference to FIG. 5 will show that there is an acute angle a between an edge 100 of the triangular surface and the circumference of the O.D. which ideally suits the intended "pumping" function of the surfaces 98. A preferred range of angles for a which will work with the arrangement are between 10° and 30°, and the preferred embodiment will have a angle a equal to about 15°. As the ring rotates, the leading edge of raised or offset surfaces 98 act as skimmers on the fluid at the high pressure side and pump or impel the fluid inwardly from the circumference.
Referring again to FIGS. 6A and 6B, the fluid being pumped from the O.D. reaches the first or outermost microdam 96 which acts as a fluid barrier. The relative pressure is greater at the point closest to the outer wall of the microdam 96. The pressure then drops across the barrier formed by the microdam 96 until the inner wall of the microdam defining the next grooved surface 94 is reached.
It is understood that each microdam 96 is at an acute angle to the tangent normal to a given radius which touches the circumference of the seal face at that given radius. Thus, the fluid in each of the grooved surfaces 94 is pumped inwardly by the microdams 96 as the ring 76' rotates and a slight increase in pressure results from the inward pumping. As each microdam 96 acts as a barrier, there is a corresponding pressure drop across each microdam 96. The relative pressure in the grooved surfaces 94 also decreases as the measurements are taken at a surface from close to the outer diameter toward one at the inner diameter. The pressure barriers resulting from step decreases, generated by the microdams 96 as is shown in the pressure profile of FIG. 6B, provides for a minimum of fluid leakage across the surface of the ring 76'.
As in conventional groove face seals, the dam portion 82' experiences the greatest pressure drop across the surface and allows the pressure to drop to atmospheric pressure P ATM . The pressure drop across the dam 82' is smaller, however, because the step decreases have reduced the relative pressures between the outer wall formed by the dam 82' and the inner diameter. The decrease in the amount of pressure drop further reduces the amount of total fluid leakage from a seal utilizing the inventive microdam structure.
The fluid pressure analysis made above with regard to the embodiment shown in FIGS. 5 and 6A would be applicable also to seal face pattern as shown in the embodiment of FIGS. 3 and 4. The differences in the structure, e.g. the land surfaces 88 provided in the embodiment of FIGS. 3 and 4, allow for more of a channeling of the fluid flow in a spiral direction as rotation is begun of the ring 76 shown in FIGS. 3 and 4. Otherwise the microdams achieve the same function of providing a series of step decreases in the pressure as taken from the outer diameter toward the inner diameter.
The microdams also provide the capability for rotation of the sealing ring in either the clockwise or counterclockwise directions. The microdams not only build pressure at the barriers, but also restrict fluid flow, such as air flow, from the atmosphere side toward the high pressure side.
Of course, other alternative arrangements will become apparent to a person of ordinary skill in the art after acquiring a full understanding of the present invention. For example, the microdams can be utilized in unidirectional, spiral groove seal faces. Other changes, such as placing the spiral grooves on the stationary ring or placing the dams 82 or 82' at atmospheric pressure at the outer diameter and having the pumping surfaces 98 at the inner diameter, are also within the scope of this invention.
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A seal face of a ring used in a non-contacting, gap-type seal having an annular groove area with microdams, each having a preferable width of about 0.025 inches, between a plurality of groove surface areas. The microdams provide a boundary to the groove surface areas whereby the recess of each groove surface area bounded by the microdams acts as a unitary pressure zone and the pressure in the separate zones decreases in a series of steps as measured from one circumference of the ring to the other circumference.
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BACKGROUND OF THE INVENTION
The present invention relates to a base body of a reflecting mirror and a method for the preparation thereof. More particularly, the invention relates to a base body of a large-sized reflecting mirror used in reflecting astronomical telescopes and for collimation or diffusion of light beams, which is characterized by outstandingly light weight and still is free from any adverse influences on the dimensional precision and accuracy of the mirror surface due to mechanical deformation by the weight of the body per se and changes in the ambient temperature, as well as to a method for the preparation of such a base body of a reflecting mirror.
Reflecting mirrors in the prior art used in astronomical telescopes or for collimation or diffusion of light beams are prepared by lapping and polishing a surface of a mirror base made from fused quartz glass or high-silica glass to have a surface with flatness or a specified curvature of high precision, and providing the thus polished surface of the base body with a reflecting layer of a metal such as aluminum by the method of, for example, chemical vapor deposition at a temperature of 400° to 800° C. to give a reflecting surface. Such a reflecting mirror is used usually by being mounted on a supporting stand in a movable or rotatable fashion to facilitate taking a desired disposition, It is essential for the base body of a reflecting mirror that the base body has such physical properties that the accuracy of the mirror surface is not affected by various outer conditions such as changes in the ambient temperature to cause thermal expansion or shrinkage and changes in the disposition of the mirror to cause mechanical deformation of the base body by gravity.
When the reflecting mirror is relatively small, for example, having a diameter of 20 cm or smaller, the above mentioned requirements for the mirror base can be readily satisfied. Along with the recent trend that reflecting mirrors of larger and larger size, for example, having a diameter of 1 meter or even larger are demanded with an object to enhance the efficiency of the mirror system, the above mentioned requirements for the mirror base can be satisfied with increasing difficulties to ensure high accuracy of the reflecting surface. Namely, other than the high temperature at which the vapor deposition of the metal layer for the reflecting surface is performed, even a very slight change in the temperature of the mirror body caused by the changes in the ambient temperature and by the irradiation with high-energy light beams may cause a great thermal expansion of the base body so that the mirror surface is sometimes subject to warping or undulation resulting in a decrease in the performance of the reflecting mirror. This is the reason that the mirror base is formed from fused quartz glass or high-silica glass having an outstandingly small thermal expansion coefficient.
Besides the above mentioned thermal expansion or shrinkage, another serious problem in a large-sized reflecting mirror is the mechanical deformation of the mirror base, because a large-sized reflecting mirror naturally has a large weight, so that the mirror base is under a great influence of gravity to cause deformation of the mirror base in different ways as the disposition of the mirror is changed by being rotated or moved on the supporting stand. Accordingly, various attempts and proposals have been made in the prior art for decreasing the body weight of a reflecting mirror by the improvement of the structure of the base body of the mirror without sacrifice in the mechanical strength as a support of the reflecting surface, to comply with the practical requirement to ensure good operability of a large-sized reflecting mirror having a glass-made mirror base.
For example, Japanese Patent Publication 63-57761 discloses a light-weight glass-made base body of a reflecting mirror for astronomical telescopes, which consists of a front plate, i.e. the surface plate for forming the reflecting surface by metal plating thereon, a rear plate or backing plate as a base for supporting the front plate and a latticework therebetween composed of a plural number of rows of pipes made from fused quartz glass. In the latticework of pipes, each pipe of the pipe rows is contacted in a cross-stitch arrangement with the two pipes in the respective adjacent rows forming contacting lines or contacting zones while the wall thickness of the pipes is smaller along the above mentioned contacting lines or zones than in the other portions of the pipe walls and the pipes are joined together into an integral latticework by welding along the contacting lines or zones. Such a complicated latticework structure of the intermediate layer between the front plate and the rear plate of the base body, however, is industrially very disadvantageous because of the very large costs for the preparation thereof. In addition, the mirror base having such a latticework structure has poor mechanical strength in the direction within the surface plane so as not to withstand the high-precision lapping and polishing works of the optical surface, before plating with a metal, to have a desired flatness or curvature of the reflecting surface.
Moreover, it is a very difficult matter to obtain the pipe elements forming the latticework having an exactly equal effective height so that the front plate after polishing supported by the latticework unavoidably retains a strain corresponding to the height difference in the pipe elements forming the latticework to cause deformation or undulation of the reflecting surface after lapse of a certain length of time. The rigidity or such a latticework is of course inherently anisotropic and differs between the directions perpendicular to and parallel with the reflecting surface, so that the reflecting mirror having such a base body can hardly be used when the mirror must take different dispositions by being rotated or moved on the supporting stand due to the poor accuracy of the reflecting surface when the disposition of the mirror is varied.
Further, Japanese Patent Publication 61-26041 discloses another light-weight glass-made base body of a reflecting mirror for astronomical telescopes. The base body of fused quartz glass also consists of a front plate, a rear plate and an interposed latticework layer therebetween integrated into a body by welding. The latticework is prepared by putting plate-formed and/or tubular lattice elements on a supporting plate to form a lattice and filling the spaces formed between or surrounded by the lattice elements with tiny pieces of the same glass susceptible to sintering, followed by sintering of this assemblage as fastened with a graphite ring in a furnace under a non-oxidizing atmosphere. The thus prepared latticework is sandwiched between the front plate and the rear plate and welded together into an integral base body to be finished by polishing the surface of the front plate. Such a base body of a reflecting mirror is industrially disadvantageous and not practical due to the very lengthy and troublesome procedure of manufacture, with consequently very high costs, in addition to the problem that the front plate bonded to the latticework by welding retains substantial strains at the welded portions to greatly affect the dimensional accuracy of the reflecting surface.
SUMMARY OF THE INVENTION
The present invention accordingly has an object to provide a novel base body of a reflecting mirror having an outstandingly light weight and still having excellent stability against mechanical as well as thermal changes in its dimensions to ensure good operability and high performance of the reflecting mirror prepared by metal-plating on the polished surface of the base body, as well as to provide a method for the preparation of such a base body of a reflecting mirror.
Thus, the base body of a reflecting mirror provided by the invention is an integral body comprising:
(A) a front plate having an optically flat or curved surface made from fused quartz glass or high-silica glass; and
(B) a porous foamed body of fused quartz glass or high-silica glass bonded to the surface of the front plate opposite to the optically flat or curved surface.
It is preferable that the porous foamed body bonded over the whole surface to the front plate has a bulk density in the range from 0.1 to 1.1 g/cm 3 and the porosity thereof mainly consists of closed cells or, more preferably, at least 15% by volume of the porosity consists of closed cells.
The above defined base body of a reflecting mirror is prepared by the method comprising the steps of:
(a) laying a front plate having an optically flat or curved surface made from fused quartz glass or high-silica glass and a porous foamed body of fused quartz glass or high-silica glass one on the other, with the surface of the front plate opposite to the optically flat or curved surface facing the porous foamed body, with an interposed layer of a finely divided silica powder therebetween; and
(b) heating the assemblage of the front plate and the porous foamed body sandwiching the layer of the finely divided silica powder at a temperature higher than the softening point of the silica powder so as to integrate the front plate and the porous foamed body.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the base body of a reflecting mirror according to the invention, of which the optical surface of the front plate is flat, and
FIG. 2 is a radial cross sectional view of the same.
FIG. 3 is a radial cross sectional view of a base body of a reflecting mirror as another embodiment of the invention in which the base body has a rear plate integrated thereto.
FIG. 4 is a radial cross sectional view of a base body of a reflecting mirror as a further embodiment of the invention in which the front plate has a concavely curved optical surface and the base body has a rear plate and a side-reinforcing layer of glass integrated thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is described above, the essential components forming the inventive base body of a reflecting mirror include (A) a front plate having an optically flat or curved surface made from fused quartz glass or high-silica glass; and (B) a porous foamed body of fused quartz glass or high-silica glass bonded to the surface of the front plate opposite to the optically flat or curved surface.
The front plate is a plate on which a highly reflective layer of a metal such as aluminum is formed by the method of vapor deposition to give an optical reflecting surface. Therefore, the front plate must have a surface having optical flatness or desired curvature depending on the types of the mirror which may be concave or convex having a specified focal length in compliance with the intended use of the reflecting mirror. The front plate is made preferably from transparent fused quartz glass having as high as possible purity or a purity of at least 99% by weight. When it is made from high-silica glass, the content of silicon dioxide in the high-silica glass is desirably at least 70% by weight. The thickness of the front plate naturally depends on the size of the reflecting mirror, and such thickness is desirably larger in a front plate having a larger diameter in order to ensure good mechanical strength although an excessively large thickness thereof is undesirable due to the increased weight so as not to meet the requirement for a light-weight mirror base. It is of course desirable that the glass forming the front plate is free from any bubbles and has high transparency. The thickness also depends on the thickness of the porous foamed disc body to which the front plate is bonded all over the surface. For example, the thickness of the front plate is in the range from 2% to 20% of the total thickness of the front plate and the porous foamed disc body, assuming that the porous foamed body has a form of a board or slab having two parallel surfaces with a uniform thickness.
The above described front plate of fused quartz glass or high-silica glass is bonded to a porous foamed disc body of also fused quartz glass or high-silica glass of equally high purity. The porous body should have a bulk density in the range from 0.1 to 1.1 g/cm 3 , and at least 15% or, preferably, at least 30% or, more preferably, at least 60% of the porosity thereof is provided by closed cells. The volume fraction of the closed cells in the overall porosity of the porous body can be readily determined from the values of the bulk density, true density of silica or high-silica glass forming the matrix of the porous body and volume of the open cells determined by immersing the porous body in a liquid such as water. When the volume fraction of closed cells is sufficiently high, the closed cells may form a three-dimensional network structure which is anisotropically highly resistant against outer forces in every direction. When the bulk density of the porous body is too small, the mechanical strength of the porous body would be unduly low so that no reliable support can be provided as a base of the front plate to have the reflecting surface. When the bulk density thereof is too high, on the other hand, the body weight of the base body is naturally too large so as not to meet the requirement for decreasing the weight of a large-sized reflecting mirror. The closed cells should desirably have a diameter in the range from 0.01 mm to 3 mm. When the closed cells are too coarse, the mechanical strength of the porous body would be decreased, while a porous body formed from too fine closed cells cannot be light enough to meet the requirement for a light-weight base body. The porous foamed body is usually in the form of a disc or slab having upper and lower surfaces parallel to each other though not limitative thereto. For example, the upper surface can be inclined relative to the lower surface depending on the particular fashion of installation of the reflecting mirror in the optical instrument. When the porous foamed body is in the form of a disc or slab, the thickness of the porous foamed body is not particularly limitative but it is usual that the thickness thereof is in the range from 80% to 98% of the total thickness of the base body.
The porous foamed disc body of fused quartz glass or high-silica glass can be prepared according to a procedure known in the art. For example, a powder of fused quartz glass consisting of silicon dioxide having hydroxy groups is heated in an atmosphere of ammonia to be reacted therewith followed by shaping into a desired form and sintering. Alternatively, a powder of fused quartz glass is first shaped into a form and sintered and the sintered body is then ammoniated by heating in an atmosphere of ammonia. Thereafter, the ammoniated sintered body is heated in an electric furnace at a temperature of 1500° to 1800° C. to cause softening or melting of the ammoniated silicon dioxide which is expanded by the gas evolved from the glass to give a porous foamed body of which the porosity mainly consists of closed cells. Further alternatively, a foamed porous body of glass can be prepared by heating a blend of a glass powder and a blowing agent at a temperature sufficiently high to cause decomposition of the blowing agent to evolve a gas and to cause softening of the glass powder. At any rate, it is important in these processes that the conditions of foaming should be selected so as to obtain closed cells having an adequate diameter and to prevent predominance of open cells by excessively increasing the temperature.
The porous foamed body of glass obtained in the above described manner is then cut into a desired form such as a circular disc or square or rectangular slab depending on the size and form of the reflecting mirror to be prepared therefrom. The porous foamed body of glass is bonded, on one surface, to the front plate of transparent fused quartz glass or high-silica glass to provide the optical surface. Accordingly, it is necessary that the surface of the porous foamed body is shaped to have a form capable of being contacted with the surface of the front plate opposite to the optically flat or curved surface as closely as possible so that they can fit each other over substantially their whole surfaces as completely as possible.
In the bonding work of the front plate and the porous foamed disc body as the support, they are laid one on the other with an interposed layer of a finely divided silica powder having a uniform thickness of, for example, from 1 to 3 mm formed by spreading the powder all over the surface, or in an amount of the finely divided silica powder spread over the surface in the range from 2 to 200 g/m 2 or, preferably, from 30 to 100 g/m 2 . When the thickness of the silica powder layer is too small, no complete bonding can be obtained between the front plate and the porous foamed disc body while, when the thickness is too large, some decrease is caused in the bonding strength. The silica powder should have an average particle diameter as fine as possible or, preferably, not exceeding 10 μm. The silica powder should have a softening point lower than that of the porous foamed body of glass, preferably, by 50° to 100° C., or the softening point of the silica powder should be in the range from 1550° to 1800° C. or, preferably, from 1600° to 1700° C. When the softening point is higher than that of the porous glass body, the porous foamed disc body may cause deformation or may be subject to bursting of the closed cells before the silica powder layer is softened. In this regard, silica powders having a specific surface area of at least 5 m 2 /g or, preferably, at least 20 m 2 /g should be used. Silica powders produced by the so-called sol-gel method are suitable. In particular, so-called fumed silica and precipitated silica fillers having a specific surface area of, for example, at least 50 m 2 /g, which can be softened usually at 1400° to 1700° C., are quite satisfactory for this purpose.
The thus obtained assemblage of the front plate, porous foamed disc body and interposed layer of the finely divided silica powder is then mounted on a surface plate of, for example, graphite and heated at a temperature higher than the softening point of the silica powder but lower than the softening point of the porous body of glass for a length of time of from about 1 to about 4 hours under pressing by mounting a suitable weight of, for example, graphite thereon, so that the silica powder is softened or melted to act as an adhesive between the front plate and the porous body. Since the thickness of the silica powder layer is so small, it is usual that the molten silica powder is absorbed by the porous glass body so that substantially no layer of the molten silica powder as an adhesive can be found at the interface between the front plate and the porous body after the bonding treatment. It is desirable in the thus bonded interface that the effective bonding area at the cell walls is at least 5% or, preferably, at least 20% of the overall apparent bonding area, the balance being the areas of the pore spaces of the cells in the porous body.
The thus prepared composite body, which is illustrated in FIG. 1 by a perspective view and in FIG. 2 by a radial cross sectional view, consisting of the front plate 1 and the porous foamed disc body 2, has high mechanical strength suitable for the lapping and polishing works of the optical surface prior to plating of the optical surface with a layer 3 of a metal such as aluminum and silver to form a reflecting surface. If desired, another plate 4 of fused quartz glass or high-silica glass, called a rear plate or backing plate, can be bonded to the surface of the porous foamed disc body 2 opposite to the front plate 1 as is illustrated in FIG. 3 by a radial cross sectional view, so that the composite body can be imparted with further increased mechanical strength. The quality or purity of the fused quartz glass or high-silica glass forming the rear plate 4 need not be so high as in the front plate 1, and presence of a small number of bubbles or some opacity has no particular adverse influences. The method for bonding of the rear plate 4 to the porous foamed disc body 2 can be substantially the same as in the bonding work of the front plate 1 to the porous body 2.
As is illustrated in FIG. 4 by a radial cross sectional view, the mirror base illustrated in FIG. 3 can be further provided with a hoop-like reinforcing layer 5 having a thickness of, for example, 1 to 5 mm surrounding and bonded to the side surface of the porous foamed disc body 2. The reinforcing layer 5 is made from fused quartz glass or high-silica glass of a quality which can be about the same as that of the rear plate 4. A convenient method for providing such a hoop-like reinforcing side layer 5 is as follows. Thus, a hoop of fused quartz glass having an adequate wall thickness and diameter is prepared by radially cutting a pipe of fused quartz glass. The inner diameter of the hoop should be somewhat larger than the diameter of the porous foamed disc body to be put into the hoop before bonding so that, when the porous foamed disc body is put inside the hoop, s small gap having a width of, for example, 0.5 to 2 mm is formed around the porous foamed disc body. This annular gap is then filled with a finely divided silica powder such as that used in bonding of the front plate and rear plate to the porous foamed disc body.
The bonding works of the front plate, rear plate and hoop-like reinforcing side layer can be performed in one step. A typical procedure therefor is as follows. In the first place, the front plate is placed on a horizontal surface plate of graphite and the finely divided silica powder is spread over the front plate to form a uniform layer of the powder. Then, the porous foamed disc body is put on the layer of the silica powder and further the silica powder is spread over the surface of the porous foamed disc body to form a second silica powder layer on which the rear plate is mounted. Then, the reinforcing hoop is put to surround the porous foamed disc body. The gap formed between the porous foamed disc body and the hoop is filled with the silica powder. After mounting a graphite weight on the rear plate, the assemblage is introduced into a furnace and heated there at a temperature to cause softening of the powder layers so that the four parts, i.e. the porous foamed disc body, front plate, rear plate and reinforcing hoop, are integrated into a base body of a reflecting mirror. It is usual that a decrease is caused in the thickness of the porous foamed disc body heated under a graphite weight so that the width of the reinforcing hoop should be somewhat smaller than the thickness of the porous foamed body before heating under the graphite weight.
In the following, the present invention is illustrated in more detail by way of examples and comparative examples.
Example 1
A carbon mold was filled with a finely pulverized silica powder of 98% purity containing about 300 ppm of hydroxy groups and having a particle diameter not to exceed 100 μm. The powder was heated at about 1400° C. for 1 hour to prepare a sintered body which was then heated in an atmosphere of ammonia gas at 800° C. for 6 hours to effect the ammoniation reaction, and then heated at 1500° C. for 2 hours so that the sintered body was softened and expanded by the gas evolved therefrom to give a porous foamed body of fused quartz glass having a bulk density of about 0.4 g/cm 3 . The volume fraction of closed cells in the overall porosity was about 61%. The closed cells had diameters ranging from 0.08 to 0.8 mm. The porous foamed body thus obtained was cut and shaped into a disc having a diameter of 500 mm and a thickness of 8 mm.
The thus prepared porous foamed disc body having flat surfaces was mounted on a fused quartz glass plate having a diameter of 500 mm and a thickness of 0.5 mm as a rear plate put on a surface plate of graphite. A layer of a finely divided silica powder was interposed between the porous disc body and the rear plate. This powder layer was formed by spreading a fumed silica filler having a specific surface area of about 50 m 2 /g (Aerosil 50, a product by Nippon Aerosil Co.) all over the surface, and the layer had a thickness of about 1 mm after gentle stamping. Further, another plate of high-quality, transparent fused quartz glass as a front plate was mounted on the porous disc body also with an interposed powder layer of the same fumed silica filler in a thickness of about 1 mm after gentle stamping. The amount of the silica powder spread over the surface was 80 g per m 2 of the surface. The thus prepared assemblage of the rear plate, porous foamed disc body and front plate on the surface plate with interposed layers of the silica filler was heated under a load of a graphite-made weight of about 12 kg at a temperature of about 1400° C. for 50 minutes so that the rear plate, porous foamed disc body and front plate were bonded together into an integral base body having a thickness of 9 mm and a diameter of 500 mm.
The base body obtained in the above described manner was evaluated for mechanical strength and stability by the testing procedures described below.
Test 1
The base body was mounted on a horizontal surface plate with the front plate facing upwardly and a weight of 500 kg was placed on the central circular zone of 50 cm 2 area and kept as such for 3 minutes at room temperature to measure the depression at the center of the body under weight and the residual depression after the weight was removed. The results were that the depression at the center under load was 0.4 μm and substantially no residual strain was found after removal of the 500 kg weight.
Test 2
The base body was horizontally supported at two radially opposite points and kept at room temperature without mounting a weight to measure the depression of the plate at the center by the body weight of the plate per se. The result was that the depression at the center was 1 μm.
Test 3
The base body was horizontally supported in the same manner as in Test 2 and an increasing weight was mounted on the central circular zone of 3 cm 2 area to record the relationship between the weight added and depression of the plate at the center as well as the weight when the plate was broken. The result was that the depression at the center of the plate was 0.1 mm, 0.2 mm, 0.4 mm and 2 mm under the load of 0.1 kg, 0.5 kg, 1.0 kg and 5.0 kg, respectively. As a rough standard, a plate capable of withstanding a weight of 1.0 kg in this test would be acceptable for practical use of the reflecting mirror of 500 mm diameter.
Example 2
The experimental procedure was substantially the same as in Example 1 except that expansion of the ammoniated and sintered body of the fused quartz glass powder was performed at 1600° C. instead of 1500° C. The thus obtained porous foamed body had a bulk density of about 0.1 g/cm 3 and about 75% by volume of the porosity was provided by closed cells having diameters in the range from 0.08 to 1.0 mm.
The results of the tests undertaken in the same manner as in Example 1 were that the depression at the center of the base body was 0.8 μm under the 500 kg weight and the residual depression after removal of the weight was 0.1 μm in Test 1 and the depression of the front plate at the center was 1.5 μm in Test 2. The result of Test 3 was that the depression of the plate at the center was 0.1 mm, 0.3 mm and 0.6 mm under the load of 0.1 kg, 0.5 kg and 1.0 kg, respectively, and cracks were formed in the plate by mounting a weight of 5.0 kg.
Example 3
The experimental procedure was substantially the same as in Example 1 except that expansion of the ammoniated and sintered body of the fused quartz glass powder was performed at 1450° C. instead of 1500° C. The thus obtained porous foamed body had a bulk density of about 0.9 g/cm 3 and about 60% by volume of the porosity was provided by closed cells having diameters in the range from 0.01 to 0.8 mm.
The results of the tests undertaken in the same manner as in Example 1 were that the depression at the center of the base body was 0.1 μm under the 500 kg weight and substantially no residual depression was found after removal of the weight in Test 1 and the depression of the front plate at the center was 2 μm in Test 2.
Comparative Example 1
The experimental procedure was substantially the same as in Example 1 except that expansion of the ammoniated and sintered body of the fused quartz glass powder was performed at 1700° C. instead of 1500° C. The thus obtained porous foamed body had a bulk density of about 0.05 g/cm 3 and about 68% by volume of the porosity was provided by closed cells having diameters in the range from 0.08 to 3.0 mm.
The results of the tests undertaken in the same manner as in Example 1 were that the depression at the center of the base body was 2.2 μm under the 500 kg weight and the residual depression after removal of the weight was 1.2 μm in Test 1 and the depression of the front plate at the center was 0.8 μm in Test 2.
Comparative Example 2
The experimental procedure was substantially the same as in Example 1 except that expansion of the ammoniated and sintered body of the fused quartz glass powder was performed at 1400° C. for 3 hours instead of 1500° C. for 2 hours. The thus obtained porous foamed body had a bulk density of about 1.2 g/cm 3 and about 72% by volume of the porosity was provided by closed cells having diameters in the range from 0.1 to 0.6 mm.
The results of the tests undertaken in the same manner as in Example 1 were that the depression at the center of the base body was 0.1 μm under the 500 kg weight and substantially no residual depression was found after removal of the weight in Test 1 and the depression of the front plate at the center was 10 μm in Test 2.
Example 4
The experimental procedure was substantially the same as in Example 1 except that expansion of the ammoniated and sintered body of the fused quartz glass powder was performed at 1510° C. for 12 hours instead of 1500° C. for 2 hours. The thus obtained porous foamed body had a bulk density of about 0.8 g/cm 3 and about 30% by volume of the porosity was provided by closed cells having diameters in the range from 0.08 to 6.0 mm.
The results of Test 3 were that the depression of the plate at the center was 0.1 mm, 0.5 mm and 2.0 mm under the load of 0.1 kg, 0.5 kg and 1.0 kg, respectively, and the plate was broken by mounting a weight of 5.0 kg.
Example 5
The procedure for the preparation of a porous foamed body of fused quartz glass was substantially the same as in Example 1 except that the sintering temperature of the fused quartz glass powder in the carbon mold was 1100° C. and the sintered and ammoniated silica body was expanded by heating at about 1800° C. for about 10 minutes to give a porous foamed body of fused quartz glass having a bulk density of 0.12 g/cm 3 of which the volume fraction of closed cells was 16% in the overall porosity and the closed cells had diameters ranging from 0.1 to 3.0 mm.
The thus prepared porous body was cut and shaped into a disc having a diameter of 1000 mm and a thickness of 49 mm and bonded to a front plate having a diameter of 1000 mm and a thickness of 3 mm in the same manner as in Example 1 except that the temperature of the bonding work was about 1600° C. instead of 1300° C. to give a base body of a reflecting mirror. The surface of the front plate was ground and polished so that the finished front plate having an optically flat surface had a thickness of 1 mm. Thereafter, aluminum was deposited on the thus obtained optical surface by the method of chemical vapor deposition to give a reflecting mirror which had a diameter of 1000 mm and a thickness of 50 mm. The thus finished base body before deposition of aluminum on the optical surface had excellent appearance without noticeable defects. The weight of the thus prepared base body was only about 6% of that of a mirror base having the same dimensions but entirely formed from fused quartz glass without porosity.
Example 6
The procedure for the preparation of a base body of a flat reflecting mirror was substantially the same as in Example 5 except that the sintered and ammoniated body of fused quartz glass powder was expanded at a temperature of 1700° C. for 15 minutes instead of 1800° C. for 10 minutes so that the porous foamed body of fused quartz glass had a bulk density of 0.98 g/cm 3 of which the volume fraction or closed cells was 16% of the overall porosity and the closed cells had diameters ranging from 0.1 to 2.0 mm. The appearance of the thus prepared base body after polishing of the optical surface had appearance as good as in Example 5.
Example 7
The procedure for the preparation of a porous foamed body of fused quartz glass was substantially the same as in Example 5 except that the sintering temperature of the fused quartz glass powder was 1300° C. and the sintered and ammoniated body was expanded at a temperature of 1720° C. for 10 minutes instead of 1800° C. for 10 minutes so that the porous foamed body of fused quartz glass had a bulk density of 0.8 g/cm 3 of which the volume fraction of closed cells was 60% of the overall porosity and the closed cells had diameters ranging from 0.02 to 1.0 mm.
The thus obtained porous body was cut and shaped into a disc having a diameter of 1000 mm and a thickness of 40 mm and bonded to a front plate having a thickness of 12 mm in the same manner as in Example 5 to give a base body of a reflecting mirror which was subjected to grinding and polishing of the surface of the front plate followed by deposition of aluminum so that the front plate of the finished reflecting mirror had a thickness of 10 mm.
Example 8
The procedure was substantially the same as in Example 5 except that the front plate bonded to the porous foamed disc body had a thickness smaller by 1 mm than in Example 5 and a 1.0 mm thick plate of milky white fused quartz glass having a density of 2.2 g/cm 3 was bonded to the other surface of the porous foamed disc body as a rear plate in the same manner as in Example 1. The finished reflecting mirror had the same diameter and thickness as in Example 5. The weight of the thus prepared base body was only about 8% of that of a mirror base having the same dimensions but entirely formed from fused quartz glass without porosity.
Comparative Example 3
The procedure was substantially the same as in Example 5 except that sintering temperature of the fused quartz glass powder was 1000° C. and the temperature for the expansion of the ammoniated and sintered body was 1760° C. so that the porous foamed body had a bulk density of 0.8 g/cm 3 of which the volume fraction of closed cells was about 10%.
The porous foamed body shaped into the form of a disc was bonded in the same manner as in Example 7 to a front plate having a thickness of 12 mm so that the front plate of the finished reflecting mirror had a thickness of 10 mm after grinding and polishing. The overall thickness of the mirror was the same as in Example 5. The base body of the reflecting mirror before deposition of aluminum layer had a defect that separation, though very slight, was found between the front plate and the porous foamed disc body.
Comparative Examples 4 and 5
The procedure for the preparation of a base body of a flat reflecting mirror was substantially the same as in Comparative Example 3 described above in each of Comparative Examples 4 and 5 except that the porous foamed disc body had a bulk density of 0.05 g/cm 3 and 0.1 g/cm 3 , respectively, the volume fraction of closed cells was each 15% of the overall porosity and the front plate had a thickness of 1 mm and 0.5 mm, respectively, after finishing by grinding and polishing. The appearance of the base body in Comparative Example 4 after polishing had a defect similar to that in Comparative Example 3 and a small number of tiny cracks were found in the front plate in the base body of Comparative Example 5 after finishing by polishing.
The reflecting mirrors prepared in Examples 5 to 8 and Comparative Examples 3 and 4 were each subjected to the test of warping or undulation of the optical surface by the body weight when the mirror was horizontally supported at three symmetrical positions around the periphery to determine the root mean square (RMS) roughness and the maximum height in the roughness curve (Rt) in the vertical and horizontal directions. The results of the measurement are shown in Table 1 below in the unit of λ, which was the wavelength 633 nm of the light used in the measurement of the optical interference. The table also includes the data obtained with a reflecting mirror as a control having a honeycomb structure by sandwiching a latticework formed from fused quartz glass pipes having a length of 46 mm, outer diameter of 40 mm and wall thickness of 2 mm in a closed-packing arrangement between two fused quartz glass plates each having a thickness of 2 mm by welding into an integral body. The weight of this control base body was 22% of that of a mirror base having the same dimensions but entirely formed from fused quartz glass without porosity.
TABLE 1______________________________________ Vertical direction Horizontal direction RMS Rt RMS Rt______________________________________Example 5 0.06 0.24 0.07 0.28Example 6 0.02 0.18 0.06 0.30Example 7 0.03 0.11 0.04 0.28Example 8 0.03 0.12 0.04 0.20Comparative 0.03 0.14 0.14 0.92Example 3Comparative 0.09 0.82 0.66 3.55Example 4Control 0.07 0.25 0.12 0.66______________________________________
Example 9
Silicon tetrachloride was subjected to flame hydrolysis in an oxyhydrogen flame by the chemical vapor deposition method to produce silica soot and a sintered body prepared therefrom was ammoniated by heating in an atmosphere of ammonia at 800° C. The thus obtained sintered and ammoniated body of silica was heated at 1650° C. under a reduced pressure of 0.1 Torr for 3 hours so that the silica body was softened and expanded by the gas evolved therefrom into a porous foamed body of fused silica glass having a bulk density of 0.19 g/cm 3 , of which the volume fraction of closed cells was about 82% of the overall porosity. The closed cells had diameters in the range from 0.05 to 1.2 mm. The porous foamed body of fused silica glass was cut and shaped into a disc having a diameter of 506 mm and a thickness of 52 mm.
A plate of high-purity transparent fused quartz glass having a diameter of 500 mm and a thickness of 3 mm to serve as a front plate was mounted on the porous foamed disc body after spreading the same finely divided silica powder as used in Example 1 in an amount of 100 g/m 2 to form a uniform layer of the powder and a graphite plate of 20 kg weight was further mounted thereon. The assemblage was introduced into a furnace and heated at 1400° C. for about 1 hour under a reduced pressure of 0.1 Torr so that the silica powder of the interposed layer was softened and the porous foamed disc body and the front plate were firmly bonded together into an integral base body. The density of the porous foamed disc body in the thus prepared base body had been slightly increased to about 0.20 g/cm 3 due to compression in the heating process at 1400° C. This base body was finished by grinding the side surface and grinding and polishing the surface of the front plate into a mirror base having a diameter of 500 mm and thickness of 50 mm of which the thickness of the front plate was 1 mm.
The mirror base prepared in the above described manner was subjected to the measurement of the peak-and-valley height deviation using an optical interferometer by holding the same to have the optical surface in a horizontal and vertical dispositions. The results are shown in Table 2 below in the unit of λ which was the wavelength 633 nm of the light used in the interference measurement.
Example 10
A sintered body of silica soot prepared from silicon tetrachloride by the chemical vapor deposition method was ammoniated by heating at 800° C. in ammonia and then subjected to expansion by heating at 1650° C. for 3 hours under a reduced pressure of 0.1 Torr to give a porous foamed body of fused silica glass having a bulk density of 0.19 g/cm 3 and the volume fraction of closed cells in the overall porosity was about 70%. The closed cells had diameters in the range from 0.05 to 1.3 mm. This porous foamed body of fused silica glass was cut and shaped into a disc having a thickness of 52 mm and a diameter of 497 mm.
The porous foamed disc body was put into a circular hoop of fused quartz glass having an outer diameter of 504 mm, width of 48 mm and thickness of 3 mm and the porous disc body was sandwiched between two circular plates of fused quartz glass to serve, one, as a front plate and, the other, as a rear plate each having a diameter of 502 mm and a thickness of 3 mm by interposing a layer of the same finely divided silica powder as used in Example 1 between each surface of the porous disc body and the glass plate in an amount of 100 g/m 2 . The gap formed between the hoop and the porous disc body was filled with the same silica powder. This assemblage was mounted on a surface plate of graphite in an electric furnace and pressed by mounting thereon a graphite block of 20 kg weight to be heated in the furnace at 1400° C. for 1 hour under a reduced pressure of 0.1 Torr so that the four parts were bonded together into an integral base body. The thickness of the porous foamed disc body in the thus prepared base Body had been decreased to 48 mm and the density thereof had been slightly increased to about 0.20 g/cm 3 due to compression in the heating process at 1400° C.
This base body was finished by grinding the side surface and grinding and polishing the surface of the front plate into a mirror base having a diameter of 500 mm and a thickness of 50 mm of which the thickness of each of the front plate and rear plate was 1 mm.
The mirror base prepared in the above described manner was subjected to the measurement of the peak-and-valley height deviation in the same manner as in Example 9 to give the results shown in Table 2 below.
Example 11
A porous foamed body of fused silica glass, of which the bulk density was 0.57 g/cm 3 and the volume fraction of the closed cells having diameters of 0.02 to 0.8 mm was about 82% in the overall porosity, was prepared in a manner similar to Example 10. The porous foamed body was cut and shaped into a disc having a diameter of 497 mm and thickness of 52 mm. This porous foamed disc body was bonded to two plates and reinforcing hoop of fused quartz glass in the same manner as in Example 10 to give a base body of a reflecting mirror. The thickness of the porous foamed disc body in the thus prepared base body had been decreased to 48 mm and the density thereof had been slightly increased to about 0.60 g/cm 3 due to compression in the heating process at 1400° C.
This base body was finished by grinding the side surface and grinding and polishing the surface of the front plate into a mirror base having a diameter of 500 mm and a thickness of 50 mm of which the thickness of each of the front plate and rear plate was 1 mm. This mirror base was subjected to the same measurements of the peak-and-valley height deviation in the same manner as in Example 9 to give the results shown in Table 2.
Comparative Example 6
A porous foamed body of fused silica glass was prepared in substantially the same manner as in Example 10 except that expansion of the sintered and ammoniated body of silica soot was conducted at 1750° C. for 1 hour. The porous body had a bulk density of 0.045 g/cm 3 and the volume fraction of closed cells having diameters of 0.1 to 6.0 mm was 14% in the overall porosity.
This porous foamed body of fused silica glass was cut and shaped into a disc of 497 mm diameter and 52 mm thickness which was bonded together with two plates of fused quartz glass and a reinforcing hoop in the same manner as in Example 10 into an integral base body except that the graphite weight of 20 kg was replaced with that of 8 kg and heating at 1400° C. in an electric furnace was performed for 30 minutes instead of 1 hour. The thickness of the porous foamed disc body in the thus prepared base body had been decreased to 48 mm and the density thereof had ben slightly increased to about 0.050 g/cm 3 due to compression in the heating process at 1400° C.
This base body was finished by grinding the side surface and grinding and polishing the surface of the front plate into a mirror base having a diameter of 500 mm and a thickness of 50 mm of which the thickness of each of the front plate and rear plate was 1 mm. This mirror base was subjected to the same measurements of the peak-and-valley height deviation in the same manner as in Example 9 to give the results shown in Table 2.
TABLE 2______________________________________ Vertical disposition Horizontal disposition______________________________________Example 9 0.15 λ 0.26 λExample 10 0.12 λ 0.17 λExample 11 0.10 λ 0.15 λComparative 0.50 λ 0.95 λExample 5______________________________________
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A light-weight base body of a reflecting mirror, such as those used in reflecting astronomical telescopes, is proposed which is made from fused silica glass or high-silica glass and is advantageous in respect of the excellent thermal and mechanical stability in dimensions to ensure high performance of the reflecting mirror. The base body is composed of a front plate, i.e. a surface plate to provide the optical surface, and a supporting body of porous foamed glass integrally bonded to the front plate. These two parts of the base body can be bonded together by sandwiching a layer of a finely divided silica powder therebetween and heating the assemblage at a temperature higher than the softening point of the silica powder so that the silica powder is softened or melted to firmly join the two parts sandwiching the powder layer. The base body can be further improved in respect of the mechanical stability by providing a rear plate backing the porous foamed body and a reinforcing hoop-like side layer surrounding the side surface of the porous foamed body, each made from fused quartz glass or high-silica glass and bonded to the porous foamed body by utilizing melting of a layer of silica powder therebetween.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application Serial No. 60/106,421, filed Oct. 30, 1998, the disclosure of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to electrostatic atomizers and to devices in which atomization of liquid is used, including fuel atomizers and combustion devices.
BACKGROUND OF THE INVENTION
Electrostatic atomizers disperse liquid by applying a net electrical charge to the liquid, typically as a stream of the liquid passes through an orifice. The negative charges developed within the liquid tend to repel one another, dispersing the liquid into droplets. The injection of the net charge into the liquid may be accomplished utilizing a pair of opposed electrodes arranged adjacent to the stream of liquid and electrically connected to a high voltage power source. Such an electrostatic atomizer, called the SPRAY TRIODE™ atomizer, is disclosed in certain embodiments of U.S. Pat. No. 4,255,777, the disclosure of which is hereby incorporated by reference herein. Another electrostatic atomizer utilizes an electron beam to apply a net negative charge to the liquid. Certain embodiments of U.S. Pat. Nos. 5,093,602 and 5,378,957, the disclosures of which are hereby incorporated by reference herein, disclose apparatus and methods for electrostatic atomization utilizing an electron beam.
Electrostatic atomization of Newtonian fluids adheres to the following equation: D=75/ρ e . D is the mean droplet size in microns and ρ e is the charge density of the fluid, in coulombs per meter cubed. Thus, the same size droplets will be produced whenever a particular charge density is achieved.
The greater the charge density injected into the liquid, the greater the droplet dispersion, the smaller the droplet size and the narrower the droplet distribution. A limit on the charge density which can be injected into the liquid is the phenomenon of corona-induced breakdown, which interrupts dispersion of the liquid. When a critical level of charge is reached, the spray plume collapses. FIG. 7A shows a spray plume during uninterrupted operation and FIG. 7B shows a spray plume during operation interrupted by corona-induced breakdown. For a combustion device, this means interruption of the flame operating on the electrostatically atomized fuel.
For example, a combustion device has been run on fuel atomized by the SPRAY TRIODE™ electrostatic atomizer. It was found that sustained operation close, i.e., within 50V, to the critical level for corona-induced breakdown, which was about 5 kV or more, was required for blue flame operation. However, when the net charge reached the critical level, operation of the combustion device was dramatically interrupted. Furthermore, the critical level of net charge at which corona-induced breakdown occurs depends upon the properties and flow rate of the fuel, which vary during operation of the combustion system. Changes in ambient pressure and temperature also affect the operation of the electrostatic atomizer.
It would be desirable to develop an electrostatic atomizer with improvements in sustained operation and the maximum charge density provided to a liquid.
SUMMARY OF THE INVENTION
The present invention addresses these needs.
An aspect of the present invention provides an electrostatic atomizer comprising a charge injection device for injecting a net charge into a fluent material to thereby atomize the fluent material, a power source for powering the charge injection device, a controller for controlling the net charge injected by the charge injection device, and a sensor for sensing breakdown precursors in the vicinity of the orifice. The sensor produces a feedback signal upon the occurrence of the breakdown precursors, the sensor being in communication with the controller. The controller is responsive to the feedback signal so that upon occurrence of the feedback signal, the controller decreases the net charge injected.
The controller varies the net charge injected into the stream of liquid to avoid corona-induced breakdown, which interrupts the atomization of the liquid. Corona-induced breakdown occurs at a particular level of net charge for the charge injection device. By controlling the level of net charge in response to the feedback signal, corona-induced breakdown is avoided, but the system operates on the highest level of net charge which can be used without corona-induced breakdown. During the onset of corona-induced breakdown, breakdown precursors develop in the vicinity of the orifice of the electrostatic atomizer. Accordingly, when breakdown precursors are sensed, the controller reduces the level of net charge injected into the stream of liquid by a predetermined amount.
In certain preferred embodiments, the controller is arranged to progressively increase the net charge until the feedback signal occurs, decrease the net charge injected by a predetermined amount in response to the feedback signal, and then progressively increase the net charge until the feedback signal recurs. The net charge may be decreased by a predetermined amount and then progressively increased after a predetermined dwell time has lapsed. Depending on the amount of decrease applied in response to the feedback signal, the rate of progressive increase, and conditions prevailing in the fluid flow, the controller may cause the amount of charge injected to rise and fall repeatedly so that during some brief intervals, the level of charge is above the level which can be applied without corona breakdown. As further explained below, charge levels above the long-term breakdown level can be applied for short intervals. In certain preferred embodiments, the system repeatedly brings the charge level up above the long-term breakdown level, which yields breakdown precursors and triggers the feedback signal, then decreases the charge level to or below the long-term breakdown level, responsive to the feedback signal, and then raises the charge level again. The overall result is a time-average charge level above the long-term breakdown level without breakdown.
In certain preferred embodiments, the controller is arranged to vary the net charge injected so that the net charge varies in accordance with a predetermined pattern of variation until the feedback signal occurs.
In certain preferred embodiments, the charge injection device includes a first surface and a second surface spaced apart from one another and disposed within the body. The power source provides a potential difference between the first and second surfaces so that a net charge may be injected into the stream of liquid. The first electrode may comprise a conically-shaped electrode having a pointed end, or any other shape. The second electrode comprises a surface having at least one aperture formed therein. The charge injection device, in other embodiments, includes an electron gun. Any charge injection device for injecting a fluent material with a net charge may be used.
In preferred embodiments, the electrostatic atomizer further comprises a body defining an orifice, the fluent material being a stream of liquid passing out of the orifice.
The sensor, in certain preferred embodiments, includes a loop antenna encircling the orifice. In other embodiments, the body is electrically connected to the sensor for sensing the breakdown precursors. In this embodiment, the atomizer includes a housing and the body is electrically isolated from the housing.
The net charge injected into the fluent material is related to the operating voltage applied to the charge injection device. In preferred embodiments, the controller is arranged to control an operating voltage applied to the charge injection device and to vary the operating voltage so that the operating voltage progressively increases until the feedback occurs, decreases in response to the feedback signal, and then progressively increases. The operating voltage is decreased by the controller by a predetermined amount and then progressively increased after a predetermined dwell time has elapsed.
In other preferred embodiments, the controller is arranged to control the operating voltage and to vary the operating voltage in accordance with a predetermined pattern of variation until the feedback signal occurs.
The controller is arranged to vary the net charge injected in a predetermined pattern so that a base level of net charge is applied, the net charge is increased by an incremental amount of net charge to a higher level, and then the net charge is decreased to the base level. The controller maintains the base level for a first predetermined time period and maintains the higher level for a second predetermined time period. The incremental amount of net charge may have a predetermined magnitude and the controller may reduce the incremental amount to a value less than the predetermined magnitude in response to receiving a feedback signal. The controller may reset the incremental amount of net charge to the predetermined magnitude until the feedback signal recurs.
In certain preferred embodiments, the base level has a predetermined magnitude and the controller reduces the amount for the base level in response to the feedback signal to an amount less than the predetermined magnitude.
The controller is preferably connected to the power source for controlling the power source so that the power source applies the varying operating voltage. The controller preferably includes a circuit for controlling the power source and also preferably includes a DC-DC converter. The circuit preferably detects breakdown precursors by detecting the voltages applied to the sensor by the breakdown precursors.
The electrostatic atomizer may include a source of a liquid, such as a source of fuel or some other liquid in communication with the body for providing a stream of liquid to be atomized. The liquid source may be arranged to vary the flow of the stream of liquid. This aspect of the present invention incorporates the realization that the amount of charge which can be injected without breakdown varies with the flow rate, and that control of the charge injection responsive to the feedback signal allows the amount of charge inserted to follow or “track” a varying fluid flow at all times. The amount of charge injected can be at or near the maximum allowable charge without breakdown.
In another aspect of the present invention, an apparatus for controlling the operation of an electrostatic atomizer so that the net charge applied to the liquid to be atomized is controlled includes a controller in communication with a sensor. The sensor produces a feedback signal upon receipt of a precursor signal, and the controller is responsive to the feedback signal so that upon occurrence of the feedback signal the controller decreases the net charge by a predetermined amount.
The controller, in certain preferred embodiments, is arranged to progressively increase the net charge until the feedback signal occurs, decrease the net charge injected by a predetermined amount, and then progressively increase the net charge after a predetermined dwell time has expired.
In another aspect of the present invention, a method of minimizing corona-induced breakdown in an electrostatic atomizer comprises providing a fluent material with a net charge to atomize the fluent material, and responding to the occurrence of breakdown precursors by decreasing the net charge of the fluent material to avoid corona-induced breakdown. The method preferably includes the step of sensing breakdown precursors before the step of responding. The method also preferably includes the step of producing a feedback signal upon sensing precursors and decreasing the net charge in response to the feedback signal.
In certain preferred embodiments, the method includes progressively increasing the net charge until the precursors occur, decreasing the net charge in response to the precursors, and then progressively increasing the net charge until precursors recur. The net charge is preferably decreased by a predetermined amount and then progressively increased after a predetermined dwell time has elapsed.
In other preferred embodiments, the method includes the step of varying the net charge provided the fluent material so that the net charge varies in accordance with a predetermined pattern of variation until precursors occur.
The method may include providing a potential difference between two spaced surfaces to provide the fluent material with net charge. The fluent material may also be provided net charge by an electron gun, or a pair of electrodes.
The method preferably comprises sensing precursors received by a loop antenna encircling the orifice of the atomizer. The fluent material may comprise a stream of liquid having a varying flow rate. The atomizer may include a variable orifice for controlling the flow of the stream of liquid.
The method preferably comprises applying an operating voltage to a charge injection device for providing the fluent material with net charge. In preferred embodiments, the method comprises controlling the operating voltage so that the operating voltage progressively increases until precursors occur, decreases in response to precursors and then progressively increases. The operating voltage is decreased by a predetermined amount and then progressively increased after a predetermined dwell time has elapsed. In certain preferred embodiments, the method includes controlling the operating voltage so that the operating voltage varies in accordance with a predetermined pattern of variation until the precursors occur.
In preferred embodiments, a base level of net charge is preferably applied, the net charge is increased by an incremental amount to a higher level, and then the net charge is decreased to the base level. The base level is preferably applied for a first predetermined time period, and then the higher level is preferably applied for a second predetermined time period. The incremental amount of net charge preferably has a predetermined magnitude. The step of decreasing the net charge in response to precursors may include reducing the incremental amount of net charge to a magnitude less than the predetermined magnitude in response to precursors. The incremental amount will be reset to the predetermined magnitude until precursors recur.
The base level may have a predetermined magnitude and the step of reducing the net charge in response to precursors may include reducing the base level to an amount less than the predetermined magnitude. The base level may be reset at the predetermined magnitude until precursors recur.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIG. 1 is a schematic cross-sectional view of an atomizer in accordance with a first embodiment of the invention;
FIG. 2 is a schematic circuit diagram of a controller for the atomizer of FIG. 1;
FIG. 3 is a graph illustrating a predetermined pattern of variation for a controller of the atomizer of FIGS. 1-2;
FIG. 4 is a photograph of an electrostatic atomizer with a loop antenna sensor for the electrostatic atomizer of FIGS. 1-3;
FIG. 5 is a graph illustrating the operating voltage for a power source in an electrostatic atomizer of FIGS. 1-4;
FIG. 6 is a graph illustrating the dependence of the breakdown phenomenon on time;
FIG. 7A is a photograph of a spray plume for an atomized liquid uninterrupted by corona-induced breakdown;
FIG. 7B is a photograph of a spray plume for an atomized liquid interrupted by corona-induced breakdown;
FIG. 8A is a graph illustrating an isolated precursor signal;
FIG. 8B is a graph illustrating multiple precursor signals;
FIG. 8C is a graph illustrating another set of multiple precursor signals;
FIG. 8D is a graph illustrating yet another set of multiple precursor signals;
FIG. 9 is a graph illustrating the operating voltage for a power source in an electrostatic atomizer in accordance with another embodiment of the invention;
FIG. 10 is a graph illustrating the operating voltage for a power source controlled by a controller in an electrostatic atomizer in accordance with a further embodiment of the invention; and
FIG. 11 is a graph illustrating the operating voltage for a power source controlled by a controller in the electrostatic atomizer of FIGS. 1 - 5 .
DETAILED DESCRIPTION OF THE INVENTION
An electrostatic atomizer in accordance with one embodiment of the present invention is illustrated by FIG. 1 . The electrostatic atomizer 10 according to this embodiment includes a SPRAY TRIODE™ atomizer, in accordance with certain embodiments of U.S. Pat. No. 4,255,777, the disclosure of which is hereby incorporated by reference herein.
A generally cylindrical electrically conductive metallic body 11 with a central axis 14 has a liquid supply line 19 formed therein and opens into a central chamber 12 . Body 11 defines a forward wall 16 having an orifice 22 opening therethrough on central axis 14 . An electrically insulating support 38 is disposed within the central chamber 12 of body 11 . Insulator 38 is generally cylindrical and coaxial with body 11 . The insulator defines a plurality of liquid distribution channels 44 extending generally radially and a set of axially extensive grooves 49 adjacent the outer periphery of the insulator. Radial channels 44 merge with one another adjacent the central axis 14 of the insulator and body 11 and merge with the grooves 49 . Further, the radial channels 44 and axial grooves 49 communicate with the inlet passage 19 of body 11 , so that the inlet passage is in communication, via the radial channels 44 , with all the axial grooves 49 around the periphery of insulator 38 . A liquid source 37 delivers liquid to conduit 19 so that the liquid flows through channels 44 and grooves 49 to the chamber 12 . Insulator 38 may be formed of any substantially rigid dielectric material, such as a glass, non-glass ceramic, thermoplastic polymer or thermosetting polymer.
A charge injection device 21 comprises a central electrode 25 . A central electrode 25 is mounted within insulator 38 and electrically insulated from the body 11 by insulator 38 . Central electrode 25 has a pointed forward end 42 disposed in alignment with orifice 22 and in close proximity thereto. The forward tip 40 of central electrode 25 is formed from a fibrous material having electrically conductive fibers 43 extending generally in the axial direction of the electrode and of body 11 , each such fiber 43 having a microscopic point, these points cooperatively constituting the surface of tip 40 . A ground electrode 52 is mounted remote from body 11 and remote from orifice 22 . Although electrode 52 is schematically illustrated as a flat plate in FIG. 1, its geometrical form is not critical. Where the atomized liquid is directed into a vessel, pipe or other enclosure, the ground electrode may be a wall of the enclosure.
Ground electrode 52 is at a reference or ground electrical potential. The body 11 is connected via a resistor to the ground potential 47 . Tip 40 of central electrode 25 is connected to a high voltage potential source 50 . The foregoing components of the apparatus may be generally similar to the corresponding components of the apparatus called the SPRAY TRIODE™ atomizer, disclosed in certain embodiments of U.S. Pat. No. 4,255,777, the disclosure of which is hereby incorporated by reference herein.
The high-voltage power source 50 comprises a controller circuit 80 and a DC-DC converter 62 . As shown in FIG. 2, the controller circuit 80 in this embodiment includes a central processing unit (“CPU”) 63 connected to a dual digital resistor 64 . The digital resistor 64 is connected to a an analog switch 81 , which is in turn connected to an amplifier 82 . The amplifier 82 is connected to a DC-DC converter. A transistor 85 is connected to the switch 81 and the CPU 63 . A sensor comprising a loop antenna 70 in this embodiment, is connected to another amplifier 83 , as shown in FIG. 2 . Amplifiers 82 and 83 may be included in one component. The antenna may be comprised of a 5 millimeter diameter insulated wire in the shape of an open loop curving around the orifice 22 of the electrostatic atomizer. FIG. 4 shows the antenna mounted on the electrostatic atomizer.
The components utilized in the controller 80 are: microchip PIC 12C672, manufactured by Microchip Technology, Inc., Tempe, Ariz., as the CPU 63 ; Dallas Semiconductor Model DS1267, as the digital resistor 64 , manufactured by Dallas Semiconductor, Dallas, Tex., the model MM74HC4316M, manufactured by Fairchild Semiconductor, Corp., South Portland, Me. as the switch 81 ; 2N2222 power transistor as the transistor 85 ; and model LF353N, manufactured by National Semiconductor, Santa Clara, Calif., as the amplifier 82 . The DC-DC converter is a Model No. DX150N by EMCO High Voltage, Inc., 11126 Ridge Road, Sutter Creek, Calif. 95685 (the EMCO converter). Many variations of the components discussed above would produce suitable results as a controller circuit in accordance with the invention. For example, other components for adjusting the digital output of the chip 63 and producing a voltage suitable as the input for the particular DC-DC converter may be used. In addition, the controller 80 may also be used with hard-wired components. Indeed, any electrical arrangement which allows variation of the charge injection in response to a signal produced by a sensor can be used.
The CPU 63 provides a signal which is used to vary the output for the high voltage power source 50 , according to a predetermined waveform which is modified to avoid corona-induced breakdown.
During the onset of corona-induced breakdown, precursor signals develop in the vicinity of the orifice 22 of the electrostatic atomizer 10 . The precursor signals are well defined and easily detected. The precursor signals on antenna 70 typically take less than 0.1 microseconds to develop and have amplitudes of 0.5 volts or more. The antenna 70 attached to the high voltage power source 50 detects precursor signals so that the controller 80 may respond accordingly to avoid corona-induced breakdown.
Corona-induced breakdown occurs as the stream of liquid 20 exits the orifice 22 of the electrostatic atomizer 10 . Accordingly, loop antenna 70 , is preferably placed in the region of the orifice 22 at the exterior 13 of the electrostatic atomizer.
The output of the antenna 70 was measured during operation of the SPRAY TRIODET™ atomizer. The SPRAY TRIODE™ atomizer was operated utilizing a 0.75 milliliter per second stream of jet-A fuel. A single precursor signal, comprising a pulse having an amplitude of about 1 volt may develop, as shown in FIG. 8A, or, as shown in FIG. 8B, a series of precursor signals may develop during operation of the electrostatic atomizer. At a lower flow rate of 0.49 milliliters per second, some variability in the amplitude of the precursor signals is experienced, as shown in FIG. 8 C. The signals remained sharply delineated. However, as shown in FIG. 8D, the nature of the signals changes for a higher flow rate of 1.31 milliliters per second. Accordingly, it is preferred that the design of the antenna accommodate the flow range for the particular device which will incorporate the electrostatic atomizer. The loop antenna utilized in this embodiment can detect precursor signals of about 50 or more milivolts.
The CPU generates a digital output which varies according to a basic waveform, which the controller 80 translates into an operating voltage applied to the charge injection device 21 . The basic waveform is depicted in FIG. 3 . The parameters for the basic waveform shown in FIG. 3 are: the base voltage (Vb), the incremental voltage (Vi), the repetition frequency (f), and the duty cycle (d). The base voltage Vb has an initial preset value for an operating voltage lower than the critical voltage at which corona-induced breakdown will occur. The incremental voltage Vi is the amount of additional voltage applied over the base voltage to apply a higher voltage (Vh) greater than the base voltage and above the level of voltage at which corona-induced breakdown occurs. The duty cycle d is the width of a pulse (T) per unit time. These parameters are illustrated on the basic waveform in FIG. 3 . The preset values for the base voltage and incremental voltage are determined experimentally for a particular electrostatic atomizer.
The CPU 63 varies the values of the base voltage (Vb) and the incremental voltage (Vi) in response to precursor signals received by the antenna 70 . In operation, the CPU generates a digital output which varies according to the basic waveform. The CPU output causes the resistance of the digital resistor 64 , which is configured to operate in a digital to analog mode, to vary. The resistor 64 delivers a signal to the analog switch 81 which switches between either of the two voltage settings Vb and Vi. The output from the analog switch is amplified by the amplifier 82 . The amplifier thus provides a varying signal to the DC-DC converter to drive the DC-DC converter 62 . The power transistor 85 converts the low energy output from the controller to power the converter. This causes the output of the high voltage power source 50 to vary.
Upon receipt of a precursor signal by the antenna 70 , which is preferably greater than a prescribed, adjustable threshold level, a feedback signal is delivered to the CPU 63 . Upon receipt of the feedback signal, the CPU 63 requires a reduction in the incremental voltage Vi. Thus, the operating voltage applied to the charge injection device 21 follows the basic waveform, with the magnitude of the incremental voltage Vi reduced so that the magnitude of the higher voltage Vh is also reduced. The controller 80 then adjusts the value for the incremental voltage Vi to its predetermined, preset value.
Accordingly, the operating voltage applied to the charge injection device 21 varies so that the operating voltage increases from the base voltage Vb by an incremental voltage Vi to a higher voltage Vh. The higher voltage is maintained for a period of time t2, and the operating voltage is then decreased to the base voltage, which is maintained for a period of time t1. This pattern is repeated until a feedback signal is received from the sensor 70 . In response to the feedback signal, the controller 80 modifies the value of Vi to decrease the same so that corona-induced breakdown is avoided. The CPU 63 is programmed to control the high-voltage power source 50 , utilizing the above parameters and in response to the feedback signal produced by the sensor 80 , so that the operating voltage is reduced in response to a precursor signal before corona-induced breakdown fully develops. In other embodiments, the controller may be arranged to modify the preset value for the base voltage Vb.
The DC-DC converter is most preferably as agile as possible, having a high-voltage output replicating the low voltage input as accurately as possible. However, a rapid response DC-DC converter capable of varying the operating voltage before the onset of corona-induced breakdown can be used. The most preferred DC-DC converter is manufactured by Electric Research & Development Laboratory in Waterloo, Ontario, Canada, and incorporates circuitry disclosed in U.S. Pat. No. 5,631,815, the disclosure of which is hereby incorporated by reference herein (the ERDL converter). This converter produces the output shown in FIG. 9, which would be modified by the controller 80 in a similar fashion. The EMCO converter discussed above in connection with FIGS. 1-4 generates the output shown in FIG. 5 .
In a preferred embodiment of the invention, the controller 80 is programmed to progressively increase the operating voltage until a feedback signal from the antenna 70 is received by the controller. After receipt of such signal, the controller 80 requires a decrease in the operating voltage by a predetermined incremental voltage Vi to a modified level of voltage Vm. The modified level of voltage is applied for a predetermined dwell time, t4. After the dwell time t4 has elapsed, the controller 80 requires the operating voltage to increase until the receipt of another feedback signal from the sensor, when the antenna 70 receives a precursor signal. This pattern is shown in FIG. 10 . As seen in FIG. 10, the limit L at which the precursor signal occurs, causing the controller 80 to reduce the operating voltage, increases during the operation of the electrostatic atomizer. Accordingly, the operating voltage applied to the charge injection device 21 is greater, and the net charge injected into the stream of fluid 20 is therefore also greater than would be achieved by operating the charge injection device 21 on a constant voltage. As the flow rate changes, the atomizer takes into account the changing flow rate and obtains maximum net charge by increasing the charge until precursors occur.
In another embodiment of the invention, the sensor includes an electrically isolated atomizer casing for detecting precursor signals in the vicinity of the orifice 22 . In other embodiments, the sensor comprises an electrode or some other probe in the vicinity of the orifice.
In other embodiments of the invention, the electrostatic atomizer includes a charge injection device comprising an electron gun, as disclosed in U.S. Pat. Nos. 5,478,266; 5,391,958; 5,378,957; and 5,093,602, hereby incorporated by reference herein. The net charge would be varied by supplying the electron gun with a varying voltage as discussed above, or by varying the operating voltage so that the electron beam is turned on and off. Alternatively or additionally, the electron gun can include elements such as a grid to modulate the electron beam within the gun, and the grid voltage can be adjusted. For a further arrangement, two independently operable electron beams can be provided in a single gun or in dual guns, and one beam can be turned on and off repeatedly to vary the net charge injected into the liquid. In a further arrangement, an electron gun can be combined with an electrode-type (for example, a SPRAY TRIODE™ atomizer) charge injection apparatus, so that the net charge in the liquid is contributed to by both the beam and the electrodes. One source can be turned on and off, or modulated in other ways to vary the net charge injected into the liquid.
In preferred embodiments, the electrostatic atomizer includes a dielectric structure disposed between the chamber and a second electrode adjacent the orifice, as discussed in U.S. Provisional Patent Application No. 60/114,727, filed Dec. 31, 1998, the disclosure of which is hereby incorporated by reference herein. The dielectric structure insulates the second electrode from the interior space of the chamber. This arrangement reduces or eliminates buildup of residue in and around the orifice.
Preferred embodiments include the electrostatic atomizer disclosed in certain embodiments of U.S. patent Ser. No. 09/237,583, filed Jan. 26, 1999 by Arnold J. Kelly, the disclosure of which is hereby incorporated by reference herein. In certain embodiments, the flow of liquid through the orifice of the atomizer is varied through a variable orifice, comprising a sleeve having a V-shaped notch which is moveable across another element having an aperture. The intersection of the V-shaped notch and aperture form the orifice for the atomizer.
The phenomenon of corona-induced breakdown interrupts atomization and charge injection in many contexts. Thus, aspects of the present application may be applied to the atomization and charge injection of any fluent material. In addition, electrostatic atomizers in accordance with aspects of the present invention may atomize or inject charge into a number of liquid materials, such as fuel, liquid polymers, aerosols, water, or any other liquid.
As will be readily appreciated, numerous other variations and combinations of the features discussed above will be employed without departing from the present invention. Accordingly, the foregoing description of certain preferred embodiments should be taken by way of illustration, rather than by way of limitation, of the features discussed above.
EXPERIMENTAL EXAMPLE OF A PREFERRED EMBODIMENT
A SPRAY TRIODE™ electrostatic atomizer, in accordance with certain embodiments of U.S. Pat. No. 4,255,777, the disclosure of which is hereby incorporated by reference herein, was utilized in conjunction with a controller illustrated in FIG. 2, operating on jet-A fuel. The CPU 63 was programmed to generate a 90 hertz waveform having a 0.7 duty cycle. FIG. 10 shows how the operating voltage for the high-voltage power source varies over time. During the first 100 milliseconds, the atomizer operated at a voltage level close to its maximum operating voltage. At 104 milliseconds, a precursor signal was detected. The incremental voltage was decreased in response to the same. A second set of precursor signals was detected soon after, so that the controller modified the incremental voltage to a value equal to the base voltage. For about another 27 milliseconds, the electrostatic atomizer operated without the occurrence of a precursor signal. The electrostatic atomizer resumed operation at the basic waveform. After 27 milliseconds, a third precursor signal was received. The controller responded by reducing the incremental voltage. After about 30 milliseconds, operation at the basic waveform and close to the maximum voltage resumed. The spray plume maintained vigorous operation and no noticeable interruption of the spray plume was observed.
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An electrostatic atomizer comprises a power source for powering a charge injection device, a controller for controlling the net charge injected by the charge injection device, and a sensor for sensing breakdown precursors in the vicinity of the orifice and producing a feedback signal upon the occurrence of the breakdown precursors. The sensor is in communication with the controller and the controller is responsive to the feedback signal so that upon occurrence of the feedback signal, the controller decreases the net charge injected. A method of minimizing corona-induced breakdown in an electrostatic atomizer comprises the steps of providing a fluent material with a net charge to atomize the fluent material, and responding to the occurrence of breakdown precursors by decreasing the net charge of the liquid to avoid corona-induced breakdown.
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BACKGROUND
In computing systems, such as desktop computers, portable computers, personal digital assistants (PDAs), servers, and others, storage devices are used to store data and program instructions. One type of storage device is a disk-based device, such as magnetic disk drives (e.g., floppy disk drives or hard disk drives) and optical disk drives (e.g., CD or DVD drives). Such disk-based storage devices have a rotating storage medium with a relatively large storage capacity. However, disk-based storage devices offer relatively slow read-write speeds when compared to operating speeds of other components of a computing system, such as microprocessors and other semiconductor devices.
Another type of storage device is a solid state memory device, such as a dynamic random access memory (DRAM), static random access memory (SRAM), flash memory, and electrically erasable and programmable read-only memory (EEPROM). Although solid state memory devices offer relatively high read-write speeds, usually on the order of nanoseconds, they have relatively limited storage capacities.
With improvements in nanotechnology (technology involving microscopic moving parts), other types of storage devices are being developed. One such storage device is based on atomic force microscopy (AFM), in which one or more microscopic scanning probes are used to read and write to a storage medium. Typically, a scanning probe has a tip that is contacted to a surface of the storage medium. Storage of data in the storage medium is based on perturbations created by the tip of the probe in the surface of the storage medium. In one implementation, a perturbation is a dent in the storage medium surface, with a dent representing a logical “1,” and the lack of a dent representing a logical “0.” Other types of perturbations that can be created in the surface of the storage medium include creating or altering the topographic features or composition of the storage medium, altering the crystalline phase of the medium, filling or emptying existing electronic states of the medium, creating or altering domain structures or polarization states in the medium, creating or altering chemical bonds in the medium, employing the tunneling effects to move and remove atoms or charge to or from the medium, or storing/removing charge from a particular region.
One of the issues associated with a probe-based storage device is the reliability of each storage bit. Because the perturbations created to store data bits is based on some alteration of a characteristic in the surface of the storage medium, reliability of successfully generating the perturbations or detecting such perturbations can pose a challenge. For example, when a tip scans over a portion of the storage medium in which a perturbation has been created in the storage medium, the tip may miss the presence of the perturbation. As a result, a read error may occur, which reduces reliability of storage device operation. The push to create these types of devices on the nano-scale and to increase their density makes noise and reliability issues even more challenging.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a portion of a probe-based storage device that includes a storage substrate defining a storage medium, along with a probe having multiple tips to create redundant perturbations in the storage medium.
FIG. 2 is a schematic diagram of a probe substrate containing an array of probes and peripheral circuitry to interact with such probes.
FIG. 3 illustrates the probe substrate positioned to face the storage substrate in the probe-based storage device of FIG. 1 .
FIG. 4 illustrates the tips of a probe in contact with a surface of the storage medium.
FIG. 5 illustrates creation of redundant perturbations in the surface of the storage medium with the tips of the probe.
FIG. 6 illustrates the reading of the perturbations created by the probe.
FIG. 7 illustrates several probes formed in the probe substrate.
FIG. 8 is a block diagram of a system that includes a computing device having a port to connect to a probe-based storage device.
DETAILED DESCRIPTION
FIG. 1 shows an example probe-based storage device that includes a storage substrate 10 that provides a storage medium. The storage medium has a storage surface 20 on which perturbations can be formed by multiple tips 14 and 16 of a probe 12 . According to some embodiments, the probe 12 is a very small probe (on the order of micrometers, nanometers, or even smaller) that is built using nanotechnology techniques.
The tips 14 and 16 of the probe 12 are attached to and extend outwardly from a cantilever 13 of the probe 12 . Note that in some embodiments, multiple probes (such as an array of probes), each with multiple tips, are provided in the probe-based storage device. In other embodiments, a single probe with multiple tips can be provided in the probe-based storage device. As discussed further below, the probe 12 is formed from a probe substrate that is positioned in a plane that is generally parallel to the storage substrate 10 . The probe tips protrude from the main surface of the probe substrate to enable the tips to contact the storage surface 20 .
As shown in FIG. 1 , perturbations 18 are formed in the surface 20 of the storage medium on the storage substrate 10 . In one embodiment, the perturbations 18 are dents, pits, indentations, or markings formed in the surface 20 of the storage medium. In this embodiment, the material providing the surface 20 of the storage medium is formed of a relatively soft material, such as polymer (e.g., PMMA or polymethylmethacrylate). In other embodiments, the material providing the storage surface 20 of the storage medium can be a liquid crystal, a phase change material, or any other suitable material. In one implementation, the layer made of the soft material can be formed over the rest of the storage substrate 10 , with the top layer defining the storage surface 20 . Alternatively, the entire substrate 10 can be formed of the soft material.
To create the dents 18 , the tips 14 and 16 are locally heated to a predetermined temperature (e.g., up to about 400° C.) for some amount of time. The heat from the tips melts the storage surface 20 at the contact points of the tips 14 and 16 . When a downward force is applied onto the probe 12 , tips 14 and 16 imprint the dents 18 . The applied downward force can be an incremental, applied downward force, or alternatively, a constant downward force due to the elastic nature of each cantilever. For example, the device is assembled such that the cantilevers are bent back a little and are always applying some pressure on the storage substrate.
The presence of a dent represents a logical “1,” while the absence of a dent represents logical “0.” During write operations, use of the multiple tips 14 and 16 causes two redundant dents 18 to be created for each given storage cell 19 . In the example of FIG. 1 , four storage cells 19 are illustrated, with each storage cell 19 including a pair of redundant dents 18 . Note that if dents are not formed in a given storage cell 19 , then that represents a logical “0.” Alternatively, if two dents are formed in a given storage cell, then the cell represents a logical
In other embodiments, to provide even greater redundancy, a probe with more than two tips can be used for generating more than two perturbations in each storage cell. The redundant dents 18 (or other type of perturbation) in each storage cell 19 are spaced apart by a spacing defined by the distance between the probe tips 14 and 16 .
Once dents are formed, they can be erased by also using the tips 14 and 16 of the probe 12 . During erase, the tips 14 and 16 engage the dents 18 , with the tips being heated locally to melt the material surrounding the dents 18 such that the material flows into the dents to remove the dents.
Heating of the tips 14 and 16 can be achieved in one of several ways. For example, an electrical pulse can be sent along a conductor through the cantilever 13 to the tips 14 and 16 , which causes the tips 14 and 16 to be heated to the desired temperature. The heating can be achieved by local heating elements such as resistors (which heat up in response to current passing through the resistors). Alternatively, laser beams or other heat sources can be used to perform heating.
Instead of redundant dents formed in a storage cell 19 by the tips 14 and 16 of the probe 12 , other types of redundant perturbations can be created in each storage cell 19 . Perturbations can include, but are not limited to, the following: creating or altering the composition of the storage medium; altering the crystalline phase of the medium; filling or emptying existing electronic states of the medium; creating or altering domain structures or polarization states in the medium; creating or altering chemical bonds in the medium; employing tunneling effects to move and remove atoms or charge to or from the medium; or storing/removing charge from a particular region.
FIG. 2 illustrates the probe substrate 50 , which includes an array of probes 12 formed in the substrate 50 . Peripheral circuitry 52 and 54 are provided on the peripheral sides of the probe substrate 50 . For example, peripheral circuitry 52 and 54 can drive X and Y select lines to select bits of the storage array to read from or write to. A row of probes 12 may be activated by the select lines to read from or write to storage cells that the probes are in contact with. This structure enables concurrent access of multiple cells in one operation, which improves access speeds. Alternatively, one of the probes may be activated to read from or write to a storage cell. The peripheral circuitry 52 and 54 also include sensing devices and decoders to detect analog signals from the probes and to convert the analog signals to a digital representation of a logical “0” or a logical “1.”
As shown in FIGS. 1 and 3 , the probe substrate 50 is placed with the surface containing the probes 12 facing the storage surface 20 of the storage substrate 10 , on which the storage cells are formed. The probe substrate 50 is positioned over the storage substrate 10 so that the probe tips 14 and 16 ( FIG. 1 ) of each probe point downwardly to engage the storage surface 20 of the storage substrate 10 . In an alternative arrangement, the storage substrate 10 is positioned over the probe substrate 50 so that the probe tips 14 and 16 point upwardly to face the storage surface 20 . In other arrangements, the probe substrate 50 and the storage substrate 10 can be positioned laterally or diagonally.
The storage substrate 10 , in the example of FIG. 3 , is coupled to an actuator 100 that is designed to move the storage substrate 10 in both X and Y directions such that probes 12 ( FIG. 1 ) can be placed over desired storage cells on the storage substrate 10 . Data sensed by the probes 12 is provided to buffers 102 , which store output data for retrieval by an external device. The buffers 102 may also store write data to be written to storage cells 19 ( FIG. 1 ) in the storage substrate 10 .
Alternatively, the actuator 100 is operatively coupled to move the probe substrate 50 , or to move both the probe substrate 50 and the storage substrate 10 . The actuator 100 is also able to move the probe substrate 50 and/or the storage substrate 10 in the Z direction, which is generally perpendicular to the X and Y directions.
FIG. 4 is a side view of the tips 14 and 16 of the probe 12 in contact with the storage surface 20 of the storage substrate 10 . This position enables the probe 12 to write to a storage cell 19 . As shown in FIG. 5 , heating of the tips 14 and 16 and downward pressure applied onto the cantilever 13 of the probe 12 causes dents 18 to be formed in the storage surface 20 .
To read from the storage cell 19 , the cantilever 13 of the probe 12 is actuated to a slanted position (shown in FIG. 6 ), such that the cantilever 13 is at a slanted angle (not parallel) with respect to the storage surface 20 . At the slanted angle, one tip ( 14 ) is in contact with the storage surface 20 of the storage substrate 10 . In another implementation, during read operations, both tips 14 and 16 can be in contact with the storage surface 20 . The probe 12 is scanned such that the probe 14 is dragged across the storage surface 20 . The tip 14 is dragged across both the redundant dents 18 that are part of one storage cell 19 . The redundant dents increase the likelihood that the tip 14 will accurately detect presence of at least one of the dents 18 in the storage cell. Therefore, reliability is enhanced and the number of read errors resulting from mis-detection of a dent 18 is reduced.
As the probe tip is dragged across the storage surface 20 , the probe tip will deflect into the dent as the tip crosses a dent. Detection of either of the dents in the storage cell 19 is an indication of a logical “1.” In one implementation, during a read operation, the probe tip is heated to a temperature that is lower than the write temperature. When the heated probe tip encounters a dent, the probe tip transfers heat to the material of the storage surface 20 and electrical resistance falls. This reduction in electrical resistance is detected by peripheral circuitry 52 and 54 ( FIG. 2 ).
In an alternative implementation, detection of the engagement of the probe tip with the dent is based on measurement of the deflection of the cantilever 13 in response to the probe tip engaging the dent. The detection of the cantilever deflection is performed by a piezoresistive resistor that has a resistance that varies with deflection of the cantilever 13 . The piezoresistive resistor can be provided at the fixed base of the cantilever 13 . Other methods to detect deflection of the cantilever 13 can be used as well.
FIG. 7 shows several probes 12 formed in respective cavities 56 of the probe substrate 50 . This embodiment is merely one example of how probes 12 can be formed in the probe substrate 50 . Note that, in other embodiments, other techniques for forming probes in the substrate 50 can be employed. Each probe 12 is coupled to a local pivoting actuator 58 so that the probe 12 is pivotably coupled to the probe substrate 50 . Alternatively, instead of a pivoting attachment, some type of bending mechanism can be used, such as by use of a piezoresistive element that takes advantage of the inherent flexibility of the cantilever. The pivoting actuator 58 is adapted to pivot the probe 12 with respect to the storage medium surface 20 . In one position, the pivoting actuator 58 maintains the cantilever 13 of the probe 12 substantially parallel to the storage medium surface 20 (for performing write or erase operations as shown in FIGS. 4 and 5 ). In a second position, the pivoting actuator pivots the cantilever 13 such that the cantilever 13 is at a slanted angled with respect to the storage medium surface 20 (as shown in FIG. 6 ).
In another embodiment, instead of using a local pivoting actuator 58 for each probe, one pivoting actuator can be used for an entire row of probes 12 . The pivoting actuator is a microelectromechanical system (MEMS) actuator, which is based on nanotechnology. Very small structures, on the order of nanometers, are formed in the probe substrate 50 to provide the moving parts that make up the pivoting actuator 58 . The pivoting actuator 58 can be responsive to input electrical signals. For example, if the input electrical signal is at a first state, the actuator provides a first position of the cantilever 13 ; on the other hand, if the input signal is at a second state, the actuator 58 provides a second, different position of the cantilever 13 .
The probe-based storage device can be packaged for use in a computing system. For example, as shown in FIG. 8 , a probe-based storage device 200 that incorporates the multi-tip probe(s) 12 as discussed above is attached or connected to an I/O (input/output) port 202 of a computing device 204 . The I/O port 202 can be a USB port, a parallel port, or any other type of I/O port. Inside the computing device 204 , the I/O port 202 is connected to an I/O interface 206 , which in turn is coupled to a bus 208 . The bus 208 is coupled to a processor 210 and memory 212 , as well as to mass storage 214 . Other components may be included in the computing device 204 . The arrangement of the computing device 204 is provided as an example, and is not intended to limit the scope of the invention. In alternative embodiments, instead of being coupled to an I/O port of the computing system, the probe-based storage device can be mounted onto the main circuit board of the computing system.
In the foregoing description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details. While the invention has been disclosed 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 such modifications and variations as fall within the true spirit and scope of the invention.
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A storage device includes a storage medium and a probe having plural tips. The storage medium has a surface in which storage cells are to be formed. The tips of the probe form plural perturbations in the surface in at least one of the storage cells for representing a data bit.
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RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C. 119 to U.S. Provisional Application Ser. No. 60/207,874; filed May 30, 2000 and U.S. Provisional Application Ser. No. 60/226,858; filed August 22, 2000; which applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Specific interactions of cells within the extracellular matrix are critical for the normal function of organisms. Alterations of the extracellular matrix are carried out by a family of zinc-dependent endopeptidases called matrix metalloproteinases (MMPs). The alterations are carried out in various cellular processes such as organ development, ovulation, fetus implantation in the uterus, embyiogenesis, wound healing, and angiogenesis. Massova, I.; Kotra, L. P.; Fridman, R.; Mobashery, S. FASEB J 1998, 12, 1075; Forget, M. -A.; Desrosier, R. R.; Béliveau, R. Can. J Physiol. Pharmacol. 1999, 77, 465-480.
[0003] MMPs consist of five major groups of enzymes: gelatinases, collagenases, stromelysins, membrane-type MMPs, and matrilysins. The activities of MMPs in normal tissue functions is strictly regulated by a series of complicated zymogen activation processes and inhibition by protein tissue inhibitors for matrix metalloproteinases (“TIMPs”). Forget, M. -A.; Desrosier, R. R.; Béliveau, R. Can. J. Physiol. Pharmacol. 1999, 77, 465-480; Brew, K.; Dinakarpandian, D.; Nagase, H. Biochim. Biophys. Acta 2000, 1477, 267-283. Westermarck, J.; Kahari, V. M. FASEB J. 1999, 13, 781-792. Excessive MMP activity, when the regulation process fails, has been implicated in cancer growth, tumor metastasis, angiogenesis in tumors, arthritis and connective tissue diseases, cardiovascular disease, inflammation and autoimmune diseases. Massova, I.; Kotra, L. P.; Fridman, R.; Mobashery, S. FASEB J. 1998, 12, 1075; Forget, M. -A.; Desrosier, R. R.; Béliveau, R. Can. J Physiol. Pharmocol. 1999, 77, 465-480; Nelson, A. R.; Fingleton, B.; Rothenberg, M. L.; Matrisian, L. M. J. Clin. Oncol. 2000, 18, 1135.
[0004] Increased levels of activity for the human gelatinases MMP-2 and MMP-9 have been implicated in the process of tumor metastasis. Dalberg, K.; Eriksson, E.; Enberg, U.; Kjellman, M.; Backdahl, M. World J. Surg. 2000, 24, 334-340. Salo, T.; Liotta, L. A.; Tryggvason, K. J BioL Chem. 1983, 258, 3058-3063. Pyke, C.; Ralfkiaer, E.; Huhtala, P.; Hurskainen, T.; Dano, K.; Tryggvason, K. Cancer Res. 1992, 52, 1336-1341. Dumas, V.; Kanitakis, J.; Charvat, S.; Euvrard, S.; Faure, M.; Claudy, A. Anticancer Res. 1999, 19, 2929-2938. As a result, select inhibitors of MMPs (e.g., MMP-2 and MMP-9) are highly sought.
[0005] Several competitive inhibitors of MMPs are currently known. These inhibitors of MMPs take advantage of chelation to the active site zinc for inhibition of activity. Because of this general property, these competitive inhibitors for MMPs are often toxic to the host, which has been a major impediment in their clinical use. Greenwald, R. A. Ann. N. Y Acad. Sci. 1999, 878, 413-419; (a) Michaelides, M. R.; Curtin, M. L. Curr. Pharm. Des. 1999, 5, 787-819. (b) Beckett, R. P.; Davidson, A. H.; Drummond, A. H.; Huxley, P.; Whittaker, M. Drug Disc. Today 1996, 1, 16-26.
[0006] Gelatinases have been shown to function in both female ovulation and inplantation of zygotes in the womb. The female contains a pair of gonads, a system of ducts and chambers to conduct the gametes as well as to house the embryo and fetus, and external genitalia that facilitate reproductive function. The female gonads, the ovaries, lie in the abdominal cavity below most of the digestive system. Each ovary is enclosed in a tough protective capsule and contains many follicles. A follicle consists of one egg cell surrounded by one or more layers of follicle cells, which nourish and protect the developing egg cell. All of the 400,000 follicles a woman will ever have are formed at birth. Of these, only several hundred will be released during the woman's reproductive years. After puberty, one (or rarely two or more) follicle matures and releases its egg during each menstrual cycle. The cells of the follicle also produce the primary female sex hormones, the estrogen. When ovulation occurs, the egg is expelled from the follicle (much like a small volcano), and the remaining follicular tissue grows within the ovary to form a solid mass called the corpus luteum. The corpus luteum secretes progesterone, the hormone of pregnancy, and additional estrogen. If the egg is not fertilized, the corpus luteum degenerates and a new follicle matures during the next cycle.
[0007] The female reproductive system is not completely closed, and the egg cell is expelled into the abdominal cavity near the opening of the oviduct, or fallopian tube. The oviduct has a funnellike opening, and cilia on the inner epithelium lining the duct help collect the egg cell by drawing fluid from the body cavity into the duct. The cilia also convey the egg cell down the duct to the uterus, commonly called the womb. The uterus is a thick, muscular organ shaped much like an upside-down pear. It is remarkably small; the uterus of a woman who has never been pregnant is about 7 cm long and 4-5 cm wide at its widest point. The unique arrangement of muscles that make up the bulk of the uterine wall allow it to expand to accommodate a 4-kg fetus. The inner lining of the uterus, the endometrium, is richly supplied with blood vessels.
[0008] The pattern of hormone secretion controlling female reproduction differs strikingly from the male pattern, reflecting a cyclic nature of female reproduction.
[0009] Two different types of cycles occur in female mammals. Humans and many other primates have menstrual cycles, whereas other mammals have estrous cycles. In both cases, ovulation occurs at a time in the cycle after the endometrium has started to thicken and become more extensively vascularized, which prepares the uterus for the possible implantation of an embryo.
[0010] The menstrual cycle averages 28 days, but only about 30% of women have cycle lengths within a day or two of the statistical 28 days. Cycles vary from one woman to another, ranging from about 20 to 40 days. In some women the cycles are usually very regular, but in other individuals the timing varies from cycle to cycle.
[0011] Paralleling the menstrual cycle is an ovarian cycle. It begins with the follicular phase, during which several follicles in the ovary begin to grow. The egg cell enlarges and the coat of follicle cells becomes multi-layered. Of the several follicles that start to grow, only one usually continues to enlarge and mature, while the others degenerate. The maturing follicle develops an internal fluid-filled cavity and grows very large, forming a bulge near the surface of the ovary. The follicular phase ends with ovulation when the follicle and adjacent wall of the ovary rupture, releasing the egg cell. The follicular tissue that remains in the ovary after ovulation is transformed into the corpus luteum, an endocrine tissue that secretes female hormones during what is called the luteal phase of the ovarian cycle. The next cycle begins with a new growth of follicles.
[0012] Contraception literally means “against taking,” in this case, the taking in of a child. The term has come to mean preventing a pregnancy through one of several methods. These methods fall into three main categories: (1) preventing the egg and sperm from meeting in the female reproductive tract, (2) preventing implantation of a zygote, and (3) preventing the release of mature eggs and sperm from the gonads.
[0013] Besides complete abstinence, the methods that prevent release of gametes are the most effective means of birth control. Chemical contraception (birth control pills) have failure rates of less than 1%, and sterilization is nearly 100% effective. Birth control pills are combinations of a synthetic estrogen and a synthetic progestin (progesterone-like hormone). These two hormones act by negative feedback to stop the release of GnRH by the hypothalamus and FSH (an estrogen effect) and LH (a progestin effect) by the pituitary. By blocking LH release, the progestin prevents ovulation. As a backup measure, the estrogen inhibits FSH secretion so no follicles develop. Chemical contraception has been the center of much debate, particularly because of the long-term side effects of the estrogens. No solid evidence exists for cancers caused by the pill, but cardiovascular problems are a major concern. Birth control pills have been implicated in blood clotting, atherosclerosis, and heart attacks. Smoking while using chemical contraception increases the risk of mortality tenfold or more. Campbell, N.; Biology, 2nd Ed., Benjamin/Cummings Publ., Redwood City, La., 1990.
[0014] Accordingly, there is a current need for inhibitors of MMPs. Such inhibitors would be useful to treat or prevent cancer, tumor metastasis, angiogenesis in tumors, contraception, arthritis and connective tissue diseases, cardiovascular disease, inflammation or autoimmune diseases. Preferred inhibitors may exhibit selectivity for one or more specific MMPs than known competitive inhibitors. In addition, additional methods that prevent the release of gametes are needed. Suth methods will preferably not include negative long-term side-effects.
SUMMARY OF THE INVENTION
[0015] The present invention provides compounds that inhibit MMPs. Accordingly, there is provided a compound of the invention which is a compound of formula (I):
[0016] wherein
[0017] A—X—M is a hydrophobic group;
[0018] D is O, S, (C 1 -C 6 )alkyl, a direct bond, SO 2 , SO, C(═O)NR, C(═O)O, NRC(═O), or OC(═O);
[0019] E is a direct bond, (C 1 -C 6 )alkyl, (C 3 -C 8 )cycloalkyl, (C 2 -C 6 )alkenyl, or (C 2 -C 6 )alkynyl, wherein any alkyl, cycloalkyl, alkenyl, or alkynyl of E is optionally substituted with one or more (C 1 -C 6 )alkyl, hydroxy, (C 1 -C 6 )alkoxy, cyano, nitro, halo, SR, NRR, or COOR, wherein each R is independently H or (C 1 -C 6 )alkyl;
[0020] J is S or O;
[0021] G, T, and Q are each independently H, (C 1 -C 6 )alkyl, or cyano;
[0022] or a pharmaceutically acceptable salt thereof.
[0023] The present invention also provides a pharmaceutical composition that comprises a compound of formula (I) and a pharmaceutically acceptable carrier.
[0024] The present invention also provides a radiolabeled compound comprising a compound of formula (I) and a radionuclide.
[0025] The present invention also provides a pharmaceutical composition that comprises a radiolabeled compound of formula (J) and a pharmaceutically acceptable carrier.
[0026] The present invention also provides a therapeutic method for preventing or treating a pathological condition or symptom in a mammal, such as a human, wherein the activity of an MMP is implicated and inhibition of its action is desired, comprising administering to a mammal in need of such therapy, an effective amount of a compound of formula (I), or a pharmaceutically acceptable salt thereof.
[0027] The present invention also provides a method for treating or preventing cancer, angiogenesis, arthritis, connective tissue disease, cardiovascular disease, inflammation or autoimmune disease in a mammal inflicted with or at risk thereof comprising administering to the mammal in need of such treatment or prevention an effective amount of a compound of formula (I).
[0028] The present invention also provides a method for treating or preventing cancer in a mammal inflicted with or at risk thereof comprising administering to the mammal in need of such therapy an effective amount of a compound of formula (I), or a pharmaceutically acceptable salt thereof in conjunction with a chemotherapeutic agent, or a pharmaceutically acceptable salt thereof.
[0029] The present invention also provides a method for inhibiting a matrix metalloproteinase comprising a zinc atom, the method comprising contacting the matrix metalloproteinase with a compound with a group that can be activated for nucleophilic substitution by the zinc atom and can form a covalent bond with a nucleophile of the matrix metalloproteinase.
[0030] The present invention also provides a method for inhibiting a gelatinase comprising a zinc atom, the method comprising contacting the gelatinase with a compound with a group that can be activated for nucleophilic substitution by the zinc atom and can form a covalent bond with a nucleophilic site of the gelatinase.
[0031] The present invention also provides a method for imaging a tumor in a mammal inflicted with a tumor comprising administering to the mammal an effective amount of a radiolabeled compound of formula (I), or a pharmaceutically acceptable salt thereof, and detecting the presence of the radiolabeled compound.
[0032] The present invention also provides a method to image MMP activity in a tumor and/or a vasculature comprising contacting the organism (e.g., in vivo) with an effective amount of a compound the present invention, wherein the compound of formula (I) comprises a radionuclide; or a pharmaceutically acceptable salt thereof.
[0033] The present invention also provides a method for imaging MMP activity in a tumor in a mammal inflicted with a tumor comprising administering to the mammal in need of such imaging an effective amount of a compound the present invention, wherein the compound of formula (I) comprises a radionuclide; or a pharmaceutically acceptable salt thereof.
[0034] The present invention also provides a method for preventing ovulation in a mammal (e.g., human) at risk thereof comprising administering to the mammal an effective amount of a compound of formula (I).
[0035] The present invention also provides a method for preventing the implantation of a fertilized egg into the uterus of a mammal (e.g., human) in need thereof comprising administering to the mammal an effective amount of a compound of formula (I).
BRIEF DESCRIPTION OF THE FIGURES
[0036] [0036]FIG. 1 illustrates a mechanism-based inhibition of an MMP by a compound of the present invention.
[0037] [0037]FIG. 2 illustrates a synthesis of compounds of the present invention.
[0038] [0038]FIG. 3 illustrates a mechanism-based inhibition of an MMP by a compound of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl, alkoxy, alkenyl, alkynyl, etc. denote both straight and branched groups; but reference to an individual group such as “propyl” embraces only the straight chain variant, a branched chain isomer such as “isopropyl” being specifically referred to. Bicyclic aryl denotes an ortho-fused bicyclic carbocyclic substituent having about nine to ten ring atoms in which at least one ring is aromatic. Monocyclic heteroaryl encompasses a substituent attached via a ring carbon of a monocyclic aromatic ring containing five or six ring atoms consisting of carbon and one to four heteroatoms each selected from the group consisting of non-peroxide oxygen, sulfur, and N(X) wherein X is absent or is H, O, (C 1 -C 4 )alkyl, phenyl or benzyl. Bicyclic heteroaryl encompasses a substituent of an ortho-fused bicyclic heterocycle of about eight to ten ring atoms derived therefrom, particularly a benzyl-derivative or one derived by fusing a propylene, trimethylene, or tetramethylene divalent substituent thereto. Bicyclic alkyl encompasses a substituent of an ortho-fused bicyclic alkyl of about eight to ten ring atoms containing five or six ring atoms consisting of carbon and one to four ring atoms consisting of heteroatoms selected from the group consisting of non-peroxide oxygen, sulfur, and N(X) wherein X is absent or is H, O (C 1 -C 4 )alkyl, phenyl or benzyl.
[0040] It will be appreciated by those skilled in the art that compounds of the invention having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses any racemic, optically-active, polymorphic, or stereoisomeric form, or mixtures thereof, of a compound of the invention, which possess the useful properties described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase) and how to determine MMP inhibition activity using the standard tests described hereinbelow, or using other similar tests which are well known in the art.
[0041] As used herein, “ovulation” is the release of an ovum from the ovarian follicle. Stedman's Medical Dictionary, 25th Ed., Illustrated, Williams & Wilkins, Baltimore, 1990, p.1116.
[0042] As used herein, “ovum” is the female sex (reproductive) cell. When fertlized by a spermatozoon, an ovum is capable of developing into a new individual of the same species. Stedman's Medical Dictionary, 25th Ed., Illustrated, Williams & Wilkins, Baltimore, 1990, p.1116.
[0043] As used herein, “fertiliziation” is the process beginning with penetration of the secondary oocyte by the spermatozoon and completed by infusion of the male and female pronuclei. Stedman's Medical Dictionarv, 25th Ed., Illustrated, Williams & Wilkins, Baltimore, 1990, p.573.
[0044] As used herein, a “uterus” is the womb, metra, or the hollow muscular organ in which the impregnated ovum is developed into the child. Stedman's Medical Dictionary, 25th Ed., Illustrated, Williams & Wilkins, Baltimore, 1990, pp.1677-1678.
[0045] Specific and preferred values listed below for substituents (i.e., groups) and ranges are for illustration only; they do not exclude other defined values or other values within defined ranges for the substituents.
[0046] Specifically, (C 1 -C 6 )alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl; (C 1 -C 6 )alkoxy can be methoxy, ethoxy, propoxy, isopropoxy, butoxy, iso-butoxy, sec-butoxy, pentoxy, 3-pentoxy, or hexyloxy; (C 2 -C 6 )alkenyl can be vinyl, allyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,-pentenyl, 2-pentenyl, 3-pentenyl, 4-pentenyl, 1-hexenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl, or 5-hexenyl; (C 2 -C 6 )alkynyl can be ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 3-butynyl, 1-pentynyl, 2-pentynyl, 3-pentynyl, 4-pentynyl, 1-hexynyl, 2-hexynyl, 3-hexynyl, 4-hexynyl, or 5-hexynyl; (C 1 -C 6 )alkanoyl can be acetyl, propanoyl or butanoyl; (C 2 -C 6 )alkanoyloxy can be acetoxy, propanoyloxy, butanoyloxy, isobutanoyloxy, pentanoyloxy, or hexanoyloxy; (C 3 -C 8 )cycloalkyl can be cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, or cyclooctyl; aryl can be phenyl, indenyl, 5,6,7,8-tetrahydronaphthyl, or naphthyl and heteroaryl can be furyl, imidazolyl, tetrazolyl, pyridyl, (or its N-oxide), thienyl, pyrimidinyl (or its N-oxide), indolyl, or quinolyl (or its N-oxide); bicyclic aryl can be indenyl or naphthyl; monocyclic heteroaryl can be furyl, imidazolyl, triazolyl, triazinyl, oxazoyl, isoxazoyl, thiazolyl, isothiazoyl, pyrazolyl, pyrrolyl, pyrazinyl, tetrazolyl, pyridyl (or its N-oxide), thienyl, or pyrimidinyl (or its N-oxide), bicyclic heteroaryl can be quinolyl (or its N-oxide); and bicyclic alkyl can be decahydroquinoline or decahydronaphthalene (cis and trans).
[0047] As used herein, an “amino acid” is a natural amino acid residue (e.g. Ala, Arg, Asn, Asp, Cys, Glu, Gln, Gly, His, Hyl, Hyp, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr, and Val) in D or L form, as well as unnatural amino acid (e.g. phosphoserine; phosphothreonine; phosphotyrosine; hydroxyproline; gamma-carboxyglutamate; hippuric acid; octahydroindole-2-carboxylic acid; statine; 1,2,3,4,-tetrahydroisoquinoline-3-carboxylic acid; penicillamine; ornithine; citruline; α-methyl-alanine; para-benzoylphenylalanine; phenylglycine; propargylglycine; sarcosine; and tert-butylglycine) residue having one or more open valences. The term also comprises natural and unnatural amino acids bearing amino protecting groups (e.g. acetyl, acyl, trifluoroacetyl, or benzyloxycarbonyl), as well as natural and unnatural amino acids protected at carboxy with protecting groups (e.g. as a (C 1 -C 6 )alkyl, phenyl or benzyl ester or amide). Other suitable amino and carboxy protecting groups are known to those skilled in the art (See for example, T. W. Greene, Protecting Groups In Organic Synthesis ; Wiley: New York, 1981; D. Voet, Biochemistry , Wiley: New York, 1990; L. Stryer, Biochemistry , (3rd Ed.), W.H. Freeman and Co.: New York, 1975; J. March, Advanced Organic Chemistry Reactions, Mechanisms and Structure , (2nd Ed.), McGraw Hill: New York, 1977; F. Carey and R. Sundberg, Advanced Organic Chemistry, Part B: Reactions and Synthesis , (2nd Ed.), Plenum: New York, 1977; and references cited therein). According to the invention, the amino or carboxy protecting group can also comprise a radionuclide (e.g., Fluorine-18, Iodine-123, or Iodine-124).
[0048] As used herein, an “electrophile” refers to a chemical species, ion, or a portion of a compound which, in the course of a chemical reaction, will acquire electrons, or share electrons, to form other molecules or ions. Electrophiles are ordinarily thought of as cationic species (positively charged). McGraw - Hill Concise Encyclopedia of Science & Technology , McGraw-Hill, p.715, 4 th Edition, NY, N.Y. (1998).
[0049] As used herein, a “nucleophile” refers to a chemical species, ion, or a portion of a compound which, in the course of a chemical reaction, will lose electrons, or share electrons, to form other molecules or ions. Nucleophiles are ordinarily thought of as anionic species (negatively charged). Typical nucleoplic species include, e.g., hydroxyl (OH), halo (F, Cl, Br, or I), cyano (CN), alkoxy (CH 3 CH 2 O), carboxyl (COO), and thio (S). McGraw - Hill Concise Encyclopedia of Science & Technology , McGraw-Hill, p.715, 4th Edition, NY, N.Y. (1998).
[0050] As used herein, a “peptide” is a sequence of 2 to 25 amino acids (e.g. as defined hereinabove) or peptidic residues having one or more open valences. The sequence may be linear or cyclic. For example, a cyclic peptide can be prepared or may result from the formation of disulfide bridges between two cysteine residues in a sequence. A peptide can be linked through the carboxy terminus, the amino terminus, or through any other convenient point of attachment, such as, for example, through the sulfur of a cysteine. Peptide derivatives can be prepared as disclosed in U.S. Pat. Nos. 4,612,302; 4,853,371; and 4,684,620. Peptide sequences specifically recited herein are written with the amino terminus on the left and the carboxy terminus on the right.
[0051] As used herein, a “hydrophobic group” or “hydrophobic moiety” refers to a group that is relatively non-polar and will have a relatively minimal affinity for water. The nature of the hydrphobic group (i.e., A—X—M) is not important, provided the hydrophobic group fits into the pocket and has a favorable interaction (e.g., binding) with the enzyme. The hydrophobic group, while being relatively hydrophobic, can include one or more heteroatoms (e.g., S, O, or N) that can have an electrostatic charge or can include one or more groups (e.g., esters or amides) that can have an electrostatic charge, provided the hydrophobic group fits into the pocket and has a favorable interaction with the enzyme.
[0052] Any suitable hydrophobic group can be employed as A—X—M, provided the hydrophobic group fits into the pocket and has a favorable interaction (e.g., binding) with the enzyme. For example, the hydrophobic group can include a straight-chained or branched hydrocarbon chain (e.g., alkyl, alkenyl, or alkynyl), an aryl group (e.g., monocyclic or bicylic), a heteroaryl group (e.g., monocyclic or bicylic), a cycloalkyl group, an amino acid, a peptide, or a combination thereof.
[0053] In one embodiment, A—X—M can be a saturated or partially unsaturated hydrocarbon chain comprising one or more carbon atoms and optionally comprising one or more oxy (—O—), thio (—S—), sulfinyl (—SO—), sulfonyl (S(O) 2 —), or NR f in the chain, wherein each Rf is independently hydrogen or (C 1 -C 6 )alkyl. The saturated or partially unsaturated hydrocarbon chain can optionally be substituted with one or more oxo (═O), hydroxy, cyano, halo, nitro, trifluoromethyl, trifluoromethoxy, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, (C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 3 -C 8 )cycloalkyl, aryl, heteroaryl, (C 3 -C 8 )cycloalkyl(C 1 -C 6 )alkyl, (aryl)(C 1 -C 8 )alkyl, (heteroaryl)(C 1 -C 6 )alkyl, (C 3 -C 8 )cycloalkyl oxy, (aryl)oxy, (heteroaryl)oxy, (C 3 -C 8 )cycloalkyl, (aryl)oxy(aryl), (heteroaryl)oxy(heteroaryl), (C 3 -C 8 )cycloalkyl oxy (C 1 -C 6 )alkyl, (aryl)oxy (C 1 -C 6 )alkyl, or (heteroaryl)oxy (C 1 -C 6 )alkyl. In addition, any aryl, (C 3 -C 8 )cycloalkyl, or heteroaryl can optionally be substituted with one or more oxo (═O), hydroxy, cyano, halo, nitro, trifluoromethyl, trifluoromethoxy, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, (C 1 -C 6 )alkoxy(C 1 -C 6 )alkyl, (C 3 -C 8 )cycloalkyl, aryl, heteroaryl, (C 3 -C 8 )cycloalkyl(C 1 -C 6 )alkyl, (aryl)(C 1 -C 8 )alkyl, (heteroaryl)(C 1 -C 6 )alkyl, (C 3 -C 8 )cycloalkyl oxy, (aryl)oxy, (heteroaryl)oxy, (C 3 -C 8 )cycloalkyl, (aryl)oxy(aryl), (heteroaryl)oxy(heteroaryl), (C 3 -C 8 )cycloalkyl oxy (C 1 -C 6 )alkyl, (aryl)oxy (C 1 -C 6 )alkyl, or (heteroaryl)oxy (C 1 -C 6 )alkyl.
[0054] When A—X—M is a “partially unsaturated” group, such group may comprise one or more (e.g. 1 or 2) carbon-carbon double or triple bonds. For example, when A—X—M is a partially unsaturated (C 1 -C 6 )alkyl, it can be vinyl, allyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,3-butadienyl, 1-pentenyl, 2-pentenyl, 3-pentenyl, 4-pentenyl, 1-hexenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl, 2,4-hexadienyl, 5-hexenyl, ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 3-butynyl, 1-pentynyl, 2-pentynyl, 3-pentynyl, 4-pentynyl, 5-hexene-1-ynyl, 2-hexynyl, 3-hexynyl, 3-hexen-5-ynyl, 4-hexynyl, or 5-hexynyl.
[0055] A specific value for A—X—M is A and M are each independently phenyl or monocyclic heteroaryl, wherein any phenyl or heteroaryl is optionally substituted with one or more (e.g., 1, 2, 3, or 4) hydroxy, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkanoyl, (C 1 -C 6 )alkanoyloxy, (C 1 -C 6 )alkoxy, cyano, nitro, halo, trifluoromethyl, trifluoromethoxy, SR, NRR, or COOR; and
[0056] X is O S, SO, SO 2 , C(═O)NR, C(═O)O, NRC(═O), OC(═O), NR, a direct bond, or (C 1 -C 6 )alkyl optionally substituted with one or more hydroxy, (C 1 -C 6 )alkoxy, cyano, nitro, halo, SR, NRR, or COOR.
[0057] Another specific value for A—X—M is bicyclic aryl (e.g., naphthyl), bicyclic heteroaryl, or bicyclic alkyl; wherein any aryl, heteroaryl or alkyl is optionally substituted with one or more (e.g., 1, 2, 3, or 4) hydroxy, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkanoyl, (C 1 -C 6 )alkanoyloxy, (C 1 -C 6 )alkoxy, cyano, nitro, halo, trifluoromethyl, trifluoromethoxy, SR, NRR, or COOR;
[0058] wherein each R is independently H, (C 1 -C 6 )alkyl, phenyl, benzyl, or phenethyl.
[0059] A specific value for A is phenyl or monocyclic heteroaryl. Another specific value for A is phenyl.
[0060] A specific value for M is phenyl or monocyclic heteroaryl. Another specific value for M is phenyl.
[0061] A specific value for X is O, S, SO, SO 2 , C(═O)NR, C(═O)O, NRC(═O), OC(═O), NR, a direct bond, or (C 1 -C 6 )alkyl. Another specific value for X is O.
[0062] Another specific value for A—X—M is:
[0063] wherein
[0064] X′ is O, (C 1 -C 6 )alkyl (e.g., CH 2 ), or a direct bond;
[0065] Y′ is N or (C 1 -C 6 )alkyl (e.g., CH 2 ); and
[0066] Z′ is halo, (C 1 -C 6 )alkoxy (e.g., OCH 3 ), or hydroxy.
[0067] Another specific value for A-X-M is:
[0068] wherein
[0069] each W′ is independently N or CH; and
[0070] Z′ is halo, (C 1 -C 6 )alkoxy (e.g., OCH 3 ), or hydroxy.
[0071] Another specific value for A—X—M is:
[0072] wherein
[0073] n′ is about 1 to about 4; and
[0074] Z′ is halo, (C 1 -C 6 )alkoxy (e.g., OCH 3 ), or hydroxy.
[0075] Another specific value for A—X—M is:
[0076] wherein
[0077] R′ is O, (C 1 -C 6 )alkyl (e.g., CH 2 ), or S; and
[0078] m′ is about 2 to about 7.
[0079] Another specific value for A—X—M is:
[0080] wherein
[0081] n′ is about 1 to about 4.
[0082] Another specific value for A—X—M is:
[0083] wherein
[0084] R′ is O, CH 2 , or S.
[0085] A specific value for D is SO 2 .
[0086] A specific value for E is (C 1 -C 6 )alkyl. Another specific value for E is methyl.
[0087] A specific value for (C 1 -C 6 )alkyl is methyl.
[0088] A specific value for J is S.
[0089] A specific value for G is hydrogen.
[0090] A specific value for T is hydrogen.
[0091] A specific value for Q is hydrogen.
[0092] A specific compound of the present invention is a compound of formula (I) wherein A is phenyl, M is phenyl, X is O, D is SO 2 , E is methyl, J is S, G is hydrogen, T is hydrogen, and Q is hydrogen.
[0093] [0093]FIG. 2 illustrates a synthesis for compounds 1-4. 4-phenoxythiophenol 10 was prepared from the commercially available 4-phenoxyphenol 7 via the 3 step procedure illustrated by Newman and Karnes. Newman M. S.; Kames H. A. J. Org. Chem., 1996, 31, 3980-3984. Subsequent alkylation of 10 with allyl bromide, 4-bromo-1-butene and 5-bromo-1-pentene respectively, led to the sulfanyl compounds 11-13 in good yield. Although the epoxidation of 12 and 13 with mCPBA was relatively quick, taking only 2-3 days, the formation of 11 took 7 days and required a large excess of mCPBA. Finally, the conversion of the epoxides 4-6 to their corresponding thiirane derivatives 1-3, was accomplished via the treatment of each epoxide with ammoniumthiocyanate in THF/water. Although the thiiranes 2 and 3 were isolated in high yield, 93% and 85% respectively, thiirane 1 could only be recovered in a very poor (i.e., 14%) yield.
[0094] Processes for preparing compounds of formula (I) or for preparing intermediates useful for preparing compounds of formula (I) are provided as further embodiments of the invention. Intermediates useful for preparing compounds of formula (I) are also provided as further embodiments of the invention.
[0095] A compound of formula (I) wherein J is S can be prepared by treating a corresponding compound of formula (I) wherein J is 0 with a suitable sulfonating reagent. See, e.g., March, Advanced Organic Chemistry, Reactions, Mechanisms and Structure, 2 nd Ed., 1977 and Carey & Sundberg, Advanced Organic Chemistry, Part B: Reactions, 2 nd Ed., 1983.
[0096] A compound of formula (I) wherein J is O can be prepared by epoxidizing a corresponding compound of formula (I) wherein the ring that includes J is an alkene. See, e.g., March, Advanced Organic Chemistry, Reactions, Mechanisms and Structure, 2 nd Ed., 1977 and Carey & Sundberg, Advanced Organic Chemistry, Part B: Reactions, 2 nd Ed., 1983.
[0097] A compound of formula (I) wherein D is SO 2 and J is O can be prepared by oxidizing a corresponding compound of formula (I) wherein D is S. See, e.g., March, Advanced Organic Chemistry, Reactions, Mechanisms and Structure, 2 nd Ed., 1977 and Carey & Sundberg, Advanced Organic Chemistry, Part B: Reactions, 2 nd Ed., 1983.
[0098] A specific group of the compounds of the present invention, that can be activated by zinc for nucleophilic substitution and that can form a covalent bond with a nucleophile of the matrix metalloproteinase, includes a thiirane ring. Another specific group of the compounds of the present invention, that can be activated by zinc for nucleophilic substitution and that can form a covalent bond with a nucleophile of the matrix metalloproteinase, includes an oxirane ring. In addition, a specific nucleophile of the matrix metalloproteinase which can form a covalent bond with the group of the compounds of the present invention (e.g., thiirane or oxirane) is located at the amino acid residue corresponding to residue 404 of the matrix metalloproteinase, wherein the numbering is based on the active site general base for gelatinase A, which is observed in other MMPs. More specifically, the nucleophile is a carboxy (i.e., COO − ) oxygen atom located at amino acid residue corresponding to residue 404 of the matrix metalloproteinase, wherein the numbering is based on the active site general base for gelatinase A, which is observed in other MMPs. See, FIG. 1.
[0099] The matrix metalloproteinase can be a human matrix metalloproteinase. In addition, the matrix metalloproteinase can be a gelatinase, collagenase, stromelysin, membrane-type MMP, or matrilysin. Specifically, the gelatinase can be MMP-2 or MMP-9.
[0100] According to the method of the invention, the matrix metalloproteinase can be contacted with the compound, e.g., a compound of formula (I), in vitro. Alternatively, the matrix metalloproteinase can be contacted with the compound, e.g., a compound of formula (I), in vivo.
[0101] Without being bound by any particular theory, coordination of a thiirane in a compound of formula (I) with the enzyme active-site zinc ion is believed to activate the thiirane for modification by a nucleophile of the enzyme. See, FIG. 1. A computational model based on three-dimensional homology modeling for this enzyme with compound 1 indicates that the biphenyl group would fit in the active site analogously to the same group in certain known reversible inhibitors of MMP-2 and MMP-9, as analyzed by X-ray structure determination. Freskos, J. N.; Mischke B. V.; DeCrescenzo, G. A.; Heintz, R.; Getman, D. P.; Howard, S. C.; Kishore, N. N.; McDonald, J. J.; Munie, G. E.; Rangwala, S.; Swearingen, C. A.; Voliva, C.; Welsch, D. J. Bioorg. & Med. Chem. Letters, 1999, 9, 943-948. Tamura, Y.; Watanabe, F.; Nakatani, T.; Yasui, K.; Fuji, M.; Komurasaki, T.; Tsuzuki, H.; Maekawa, R.; Yoshioka, T.; Kawada, K.; Sugita, K.; Ohtani, M. J. Med. Chem. 1998, 41, 640-649. As such, the biphenyl ether moiety in compounds 1-4 is believed to fit in the P1′ subsite of gelatinases, which is a deep hydrophobic pocket. (a) Morgunova, E.; Tuuttila, A.; Bergmann, U.; Isupov, M.; Lindqvist, Y.; Schneider, G.; Tryggvason, K. Science 1999, 284, 1667-1670. (b) Massova, I.; Fridman, R.; Mobashery, S. J. Mol. Mod. 1997, 3, 17-34; Olson, M. W.; Bernardo, M. M.; Pietila, M.; Gervasi, D. C.; Toth, M.; Kotra, L. P.; Massova, I.; Mobashery, S.; Fridman, R. J. Biol. Chem., 2000, 275, 2661-2668. This binding mode brings the sulfur of the thiirane in 1 into the coordination sphere of the zinc ion. See, FIG. 1. The models also indicated that the thiirane moiety in compounds 2 and 3, with longer carbon backbones, would not be able to coordinate with the zinc ion as well as compound 1, but would fit in an extended configuration in the active site.
[0102] It is believed that the high specificity of certain compounds of the invention for a targeted enzyme arises predominantly from three factors. (i) the compounds satisfy the binding specificity requirements at the active site. In this respect these compounds are not any different from conventional reversible or affinity inhibitors. (ii) Furthermore, the structural features of the inhibition should allow it to undergo chemical activation by the zinc atom of the enzyme to generate an electrophilic species within the active site. (iii) Finally, there should be a nucleophilic amino-acid residue in the active site, in the proper orientation, to react with the electrophilic species (e.g., thiirane ring), resulting in irreversible enzyme inactivation.
[0103] By selecting a hydrophobic group (e.g., A—X—M) located a specific distance from a group (e.g., D) that can bind (e.g., hydrogen bond) with one or more sites in the enzyme (e.g., amino acid residue 191 and/or amino acid residue 192, in gelatinase A), which is in turn located a specific distance from a thiirane ring that can coordinate with the enzyme active-site zinc atom, one can prepare selective mechanism-based inhibitors for a given MMP. See, FIG. 1.
[0104] Accordingly, preferred MMP inhibitors have a hydrophobic aryl moiety (e.g., A—X—M) that can fit in the deep hydrophobic pocket (i.e., P 1 ′ subsite) of an MMP. In addition, preferred mechanism-based MMP inhibitors also have a thiirane ring that can coordinate with the enzyme active-site zinc ion, and be modified by a nucleophile (e.g., carboxylate group of amino acid residue 404 of MMP-2) in the enzyme active site. See, FIG. 1. The preferred MMP inhibitors can optionally include a second group (e.g., D) that can coordinate with one or more sites in the enzyme. Specifically, the second group can optionally hydrogen bond to the one or two proton donors (e.g., amino acid residue corresponding to residue 191 and/or amino acid residue corresponding to residue 192 of MMP-2) in the enzyme active site. See, FIG. 1.
[0105] The present invention provides a method for identifying a mechanistic based MMP inhibitor. The method includes providing a compound wherein (1) a hydrophobic moiety of the compound fits into a hydrophobic pocket of the MMP; (2) the compound has one or two groups that can hydrogen bond with one or two hydrogen donors of the MMP, wherein the hydrogen donors of the MMP are located at amino acid residue corresponding to residue 191 and amino acid residue corresponding to residue 192 of MMP-2; (3) the compound has an electrophilic group that can covalently bond with a nucleophile of the MMP, wherein the nucleophile of the MMP is located at amino acid residue corresponding to residue 404 of MMP-2; and/or (4) the compound includes a group that can coordinate with the zinc ion of the MMP.
[0106] Preferred MMP inhibitors have a thiirane or oxirane such that the sulfur or oxygen atom of the thiirane or oxirane is located about 3 angstroms to about 4 angstroms from the zinc ion. The suitable MMP inhibitors can also include a thiirane or oxirane ring located about 3 angstroms to about 5 angstroms from the active site nucleophile. See, FIGS. 1 and 3.
[0107] Radiolabeled compounds of formula (I) are also useful as imaging agents for imaging cells comprising MMP's. Accordingly, the invention also provides compounds of formula (I) that include one or more detectable radionuclides (e.g., one or more metallic radionuclide and/or one or more non-metallic radionuclides). For example, a detectable radionuclide can be incorporated into a compound by replacing an atom of the compound of formula (I) with a radionuclide (e.g., non-metallic radionuclide). Alternatively, a radiolabeled compound of the invention can be prepared by linking a compound of formula (I) to a chelating group that includes a detectable radionuclide (e.g., metallic radionuclide). Such compounds can be useful to image tissues with MMP activity or tumors, in vivo or in vitro.
[0108] As used herein, a “chelating group” is a group that can include a detectable radionuclide (e.g., a metallic radioisotope). Any suitable chelating group can be employed. Suitable chelating groups are disclosed, e.g., in Poster Sessions, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 316, No. 1386; Scientific Papers, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 123, No. 499; Scientific Papers, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 102, No. 413; Scientific Papers, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 102, No. 414; Scientific Papers, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 103, No. 415; Poster Sessions, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 318, No. 1396; Poster Sessions, Proceedings of the 46th Annual Meeting, J. Nuc.Med., p. 319, No. 1398; M. Moi et al., J. Amer. Chem., Soc., 49, 2639 (1989); S. V. Deshpande et al., J. Nucl. Med., 31, 473 (1990); G. Kuser et al., Bioconj. Chem., 1, 345 (1990); C. J. Broan et al., J. C. S. Chem. Comm., 23, 1739 (1990); C. J. Anderson et al., J. Nucl. Med. 36, 850 (1995); U.S. Pat. No. 5,739,313; and U.S. Pat. No. 6,004,533. Specifically, the chelating group can be.
[0109] As used herein, a “detectable radionuclide” is any suitable radionuclide (i.e., radioisotope) useful in a diagnostic procedure in vivo or in vitro. Suitable detectable radionuclides include metallic radionuclides (i.e., metallic radioisotopes) and non-metallic radionuclides (i.e., non-metallic radioisotopes).
[0110] Suitable metallic radionuclides (i.e., metallic radioisotopes or metallic paramagnetic ions) include Antimony-124, Antimony-125, Arsenic-74, Barium-103, Barium-140, Beryllium-7, Bismuth-206, Bismuth-207, Cadmium-109, Cadmium-1 15m, Calcium-45, Cerium-139, Cerium-141, Cerium-144, Cesium-137, Chromium-51, Cobalt-55, Cobalt-56, Cobalt-57, Cobalt-58, Cobalt-60, Cobalt-64, Copper-67, Erbium-169, Europium-152, Gallium-64, Gallium-68, Gadolinium-153, Gadolinium-157 Gold-195, Gold-199, Hafnium-175, Hafnium-175-181, Holmium-166, Indium-110, Indium-111, Iridium-192, Iron-55, Iron-59, Krypton-85, Lead-210, Manganese-54, Mercury-1 97, Mercury-203, Molybdenum-99, Neodymium-147, Neptunium-237, Nickel-63, Niobium-95, Osmium-185+191, Palladium-103, Platinum-195m, Praseodymium-143, Promethium-147, Protactinium-233, Radium-226, Rhenium-186, Rhenium-188, Rubidium-86, Ruthenium-103, Ruthenium-106, Scandium-44, Scandium-46, Selenium-75, Silver-110m, Silver-111, Sodium-22, Strontium-85, Strontium-89, Strontium-90, Sulfur-35, Tantalum-182, Technetium-99m, Tellurium-125, Tellurium-132, Thallium-204, Thorium-228, Thorium-232, Thallium-170, Tin-113, Tin-114, Tin-117m, Titanium-44, Tungsten-185, Vanadium-48, Vanadium-49, Ytterbium-169, Yttrium-86, Yttrium-88, Yttrium-90, Yttrium-91, Zinc-65, and Zirconium-95.
[0111] Specifically, the chelating group can include more than one metallic radioisotope. More specifically, the detectable chelating group can include 2 to about 10, 2 to about 8, 2 to about 6, or 2 to about 4 metallic radioisotopes.
[0112] Specifically, the non-metallic radionuclide can be a non-metallic paramagnetic atom (e.g., Fluorine-19); or a non-metallic positron emitting radionuclide (e.g., Carbon-11, Fluorine-18, Iodine-123, or Bromine-76).
[0113] Specifically, the compounds of the present invention can include more than one non-metallic radioisotope. More specifically, the compounds of the present invention can include 2 to about 10, 2 to about 8, 2 to about 6, or 2 to about 4 non-metallic radioisotopes.
[0114] A compound of formula (I), or a pharmaceutically acceptable salt thereof, can be administered to a mammal (e.g., human) in conjunction with a chemotherapeutic agent, or a pharmaceutically acceptable salt thereof. Accordingly, a compounds of formula (I) can be administered in conjunction with a chemotherapeutic agent to treat a tumor or cancer.
[0115] As used herein, a “chemotherapeutic agent” is a compound that has biological activity against one or more forms of cancer and can be administered to a patient with a compound of formula (I) without losing its anticancer activity. Suitable chemotherapeutic agents include, e.g., antineoplasts. Representative antineoplasts include, e.g., adjuncts, androgen inhibitors, antibiotic derivatives, antiestrogens, antimetabolites, cytotoxic agents, hormones, immunomodulators, nitrogen mustard derivatives and steroids. Physicians' Desk Reference, 50th Edition, 1996.
[0116] Representative adjuncts include, e.g., levamisole, gallium nitrate, granisetron, sargramostim strontium-89 chloride, filgrastim, pilocarpine, dexrazoxane, and ondansetron. Physicians' Desk Reference, 50th Edition, 1996.
[0117] Representative androgen inhibitors include, e.g., flutamide and leuprolide acetate. Physicians' Desk Reference, 50th Edition, 1996.
[0118] Representative antibiotic derivatives include, e.g., doxorubicin, bleomycin sulfate, daunorubicin, dactinomycin, and idarubicin.
[0119] Representative antiestrogens include, e.g., tamoxifen citrate and analogs thereof. Physicians' Desk Reference, 50th Edition, 1996. Additional antiestrogens include nonsteroidal antiestrogens such as toremifene, droloxifene and roloxifene. Magarian et al., Current Medicinal Chemistry, 1994, Vol. 1, No. 1.
[0120] Representative antimetabolites include, e.g., fluorouracil, fludarabine phosphate, floxuridine, interferon alfa-2b recombinant, methotrexate sodium, plicamycin, mercaptopurine, and thioguanine. Physicians' Desk Reference, 50th Edition, 1996.
[0121] Representative cytotoxic agents include, e.g., doxorubicin, carmustine [BCNU], lomustine [CCNU], cytarabine USP, cyclophosphamide, estramucine phosphate sodium, altretamine, hydroxyurea, ifosfamide, procarbazine, mitomycin, busulfan, cyclophosphamide, mitoxantrone, carboplati, cisplati, cisplatin, interferon alfa-2a recombinant, paclitaxel, teniposide, and streptozoci. Physicians' Desk Reference, 50th Edition, 1996.
[0122] Representative hormones include, e.g., medroxyprogesterone acetate, estradiol, megestrol acetate, octreotide acetate, diethylstilbestrol diphosphate, testolactone, and goserelin acetate. Physicians' Desk Reference, 50th Edition, 1996.
[0123] Representative immunodilators include, e.g., aldesleukin. Physicians' Desk Reference, 50th Edition, 1996.
[0124] Representative nitrogen mustard derivatives include, e.g., melphalan, chlorambucil, mechlorethamine, and thiotepa. Physicians' Desk Reference, 50th Edition, 1996.
[0125] Representative steroids include, e.g., betamethasone sodium phosphate and betamethasone acetate. Physicians' Desk Reference, 50th Edition, 1996.
[0126] Additional suitable chemotherapeutic agents include, e.g., alkylating agents, antimitotic agents, plant alkaloids, biologicals, topoisomerase I inhibitors, topoisomerase II inhibitors, synthetics, antiangiogenic drugs, and antibodies. See, e.g., AntiCancer Agents by Mechanism, http://www.dtp.nci.nih.gov/docs/cancer/searches/standard_mechanism_list.html, Apr. 12, 1999; Approved Anti-Cancer Agents, http://www.ctep.info.nih.gov/handbook/HandBookText/fda_agen.htm, pages 1-7, Jun. 18, 1999; MCMP 611 Chemotherapeutic Drugs to Know , http//www.vet.purdue.edu/depts/bms/courses/mcmp611/chrx/drg2no61.html, Jun. 24, 1999; Chemotherapy, http://www.vetmed.1su.edu/oncology/Chemotherapy.htm, Apr. 12, 1999; and Angiogenesis Inhibitors in Clinical Trials , http://www.cancertrials.nci.nih.gov/news/angio/table.html, pages 1-5, Apr. 19, 2000.
[0127] Representative alkylating agents include, e.g., asaley, AZQ, BCNU, busulfan, bisulphan, carboxyphthalatoplatinum, CBDCA, CCNU, CHIP, chlorambucil, chlorozotocin, cis-platinum, clomesone, cyanomorpholinodoxorubicin, cyclodisone, cyclophosphamide, dianhydrogalactitol, fluorodopan, hepsulfam, hycanthone, iphosphamide, melphalan, methyl CCNU, mitomycin C, mitozolamide, nitrogen mustard, PCNU, piperazine, piperazinedione, pipobroman, porfiromycin, spirohydantoin mustard, streptozotocin, teroxirone, tetraplatin, thiotepa, triethylenemelamine, uracil nitrogen mustard, and Yoshi-864. AntiCancer Agents by Mechanism , http://dtp.nci.nih.gov/docs/cancer/searches/standard_mechanism list.html, Apr. 12, 1999.
[0128] Representative antimitotic agents include, e.g., allocolchicine, Halichondrin B, colchicine, colchicine derivatives, dolastatin 10, maytansine, rhizoxin, paclitaxel derivatives, paclitaxel, thiocolchicine, trityl cysteine, vinblastine sulfate, and vincristine sulfate. AntiCancer Agents by Mechanism , http://dtp.nci.nih.gov/docs/cancer/searches/standard_mechanism_list.html, Apr. 12, 1999.
[0129] Representative plant alkaloids include, e.g., actinomycin D, bleomycin, L-asparaginase, idarubicin, vinblastine sulfate, vincristine sulfate, mitramycin, mitomycin, daunorubicin, VP-16-213, VM-26, navelbine and taxotere. Approved Anti - Cancer Agents , http://ctep.info.nih.gov/handbook/HandBookText/fda_agent.htm, Jun. 18, 1999.
[0130] Representative biologicals include, e.g., alpha interferon, BCG, G-CSF, GM-CSF, and interleukin-2. Approved Anti - Cancer Agents , http://ctep.info.nih.gov/handbook/HandBookText/fda_agent.htm, Jun. 18, 1999.
[0131] Representative antiangiogenic drugs include e.g., marimastat, AG3340, COL-3, neovastat, BMS-275291, TNP-470, thalidomide, squalamine, combretastatin A-4 prodrug, endostatin, SU5416, SU6668, interferon-alpha, anti-VEGF antibody, EMD121974, CAI, interleukin-12, and IM862. Angiogenesis Inhibitors in Clinical Trials , http://www.cancertrials.nci.nih.gov/news/angio/table.html, pages 1-5, Apr. 19, 2000.
[0132] Representative topoisomerase I inhibitors include, e.g., camptothecin, camptothecin derivatives, and morpholinodoxorubicin. AntiCancer Agents by Mechanism , http://dtp.nci.nih.gov/docs/cancer/searches/standard_mechanism_list. html, Apr. 12, 1999.
[0133] Additional biologicals include drugs designed to inhibit tumor vascularization, which is also known as tumor angiogenesis. These drugs can be potent antiangiogenic agents. Additional biologicals include humanized antibodies to growth factors, for example, to HER2, signaling molecules and adhesion receptors. Additional biologicals also include treatment with recombinant viruses and other means of gene therapy delivery, including for example, DNA, oligonucleotides, rybozymes, and liposomes.
[0134] Representative topoisomerase II inhibitors include, e.g., mitoxantron, amonafide, m-AMSA, anthrapyrazole derivatives, pyrazoloacridine, bisantrene HCL, daunorubicin, deoxydoxorubicin, menogaril, N, N-dibenzyl daunomycin, oxanthrazole, rubidazone, VM-26 and VP-16. AntiCancer Agents by Mechanism , http://dtp.nci.nih.gov/docs/cancer/searches/standard_mechanism_list.html, Apr. 12, 1999.
[0135] Representative synthetics include, e.g., hydroxyurea, procarbazine, o,p′-DDD, dacarbazine, CCNU, BCNU, cis-diamminedichloroplatimun, mitoxantrone, CBDCA, levamisole, hexamethylmelamine, all-trans retinoic acid, gliadel and porfimer sodium. Approved Anti - Cancer Agents , http://ctep.info.nih. gov/handbook/HandBookText/fda_agen.htm, Jun. 18, 1999.
[0136] In cases where compounds are sufficiently basic or acidic to form stable nontoxic acid or base salts, administration of the compounds as salts may be appropriate. Examples of pharmaceutically acceptable salts are organic acid addition salts formed with acids which form a physiological acceptable anion, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, α-ketoglutarate, and α-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0137] Pharmaceutically acceptable salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording a physiologically acceptable anion. Alkali metal (e.g., sodium, potassium or lithium) or alkaline earth metal (e.g., calcium) salts of carboxylic acids can also be made.
[0138] The compounds of formula (I) can be formulated as pharmaceutical compositions and administered to a mammalian host, such as a human patient in a variety of forms adapted to the chosen route of administration, i.e., orally or parenterally, by intravenous, intramuscular, topical or subcutaneous routes.
[0139] Thus, the present compounds may be systemically administered, e.g., orally, in combination with a pharmaceutically acceptable vehicle such as an inert diluent or an assimilable edible carrier. They may be enclosed in hard or soft shell gelatin capsules, may be compressed into tablets, or may be incorporated directly with the food of the patient's diet. For oral therapeutic administration, the active compound may be combined with one or more excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 60% of the weight of a given unit dosage form. The amount of active compound in such therapeutically useful compositions is such that an effective dosage level will be obtained.
[0140] The tablets, troches, pills, capsules, and the like may also contain the following: binders such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, fructose, lactose or aspartame or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring may be added. When the unit dosage form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier, such as a vegetable oil or a polyethylene glycol. Various other materials may be present as coatings or to otherwise modify the physical form of the solid unit dosage form. For instance, tablets, pills, or capsules may be coated with gelatin, wax, shellac or sugar and the like. A syrup or elixir may contain the active compound, sucrose or fructose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any unit dosage form should be pharmaceutically acceptable and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and devices.
[0141] The active compound may also be administered intravenously or intraperitoneally by infusion or injection. Solutions of the active compound or its salts can be prepared in water, optionally mixed with a nontoxic surfactant. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, triacetin, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0142] The pharmaceutical dosage forms suitable for injection or infusion can include sterile aqueous solutions or dispersions or sterile powders comprising the active ingredient which are adapted for the extemporaneous preparation of sterile injectable or infusible solutions or dispersions, optionally encapsulated in liposomes. In all cases, the ultimate dosage form should be sterile, fluid and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (e.g., glycerol, propylene glycol, liquid polyethylene glycols, and the like), vegetable oils, nontoxic glyceryl esters, and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the formation of liposomes, by the maintenance of the required particle size in the case of dispersions or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and gelatin.
[0143] Sterile injectable solutions are prepared by incorporating the active compound in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filter sterilization. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and the freeze drying techniques, which yield a powder of the active ingredient plus any additional desired ingredient present in the previously sterile-filtered solutions.
[0144] For topical administration, the present compounds may be applied in pure form, i.e., when they are liquids. However, it will generally be desirable to administer them to the skin as compositions or formulations, in combination with a dermatologically acceptable carrier, which may be a solid or a liquid.
[0145] Useful solid carriers include finely divided solids such as talc, clay, microcrystalline cellulose, silica, alumina and the like. Useful liquid carriers include water, alcohols or glycols or water-alcohol/glycol blends, in which the present compounds can be dissolved or dispersed at effective levels, optionally with the aid of non-toxic surfactants. Adjuvants such as fragrances and additional antimicrobial agents can be added to optimize the properties for a given use. The resultant liquid compositions can be applied from absorbent pads, used to impregnate bandages and other dressings, or sprayed onto the affected area using pump-type or aerosol sprayers.
[0146] Thickeners such as synthetic polymers, fatty acids, fatty acid salts and esters, fatty alcohols, modified celluloses or modified mineral materials can also be employed with liquid carriers to form spreadable pastes, gels, ointments, soaps, and the like, for application directly to the skin of the user.
[0147] Examples of useful dermatological compositions which can be used to deliver the compounds of formula I to the skin are known to the art; for example, see Jacquet et al. (U.S. Pat. No. 4,608,392), Geria (U.S. Pat. No. 4,992,478), Smith et al. (U.S. Pat. No. 4,559,157) and Wortzman (U.S. Pat. No. 4,820,508).
[0148] Useful dosages of the compounds of formula I can be determined by comparing their in vitro activity, and in vivo activity in animal models. Methods for the extrapolation of effective dosages in mice, and other animals, to humans are known to the art; for example, see U.S. Pat. No. 4,938,949.
[0149] Generally, the concentration of the compound(s) of formula I in a liquid composition, such as a lotion, will be from about 0.1-25 wt-%, preferably from about 0.5-10 wt-%. The concentration in a semi-solid or solid composition such as a gel or a powder will be about 0.1-5 wt-%, preferably about 0.5-2.5 wt-%.
[0150] The amount of the compound, or an active salt or derivative thereof, required for use in treatment will vary not only with the particular salt selected but also with the route of administration, the nature of the condition being treated and the age and condition of the patient and will be ultimately at the discretion of the attendant physician or clinician.
[0151] In general, however, a suitable dose will be in the range of from about 0.5 to about 100 mg/kg, e.g., from about 10 to about 75 mg/kg of body weight per day, such as 3 to about 50 mg per kilogram body weight of the recipient per day, preferably in the range of 6 to 90 mg/kg/day, most preferably in the range of 15 to 60 mg/kg/day.
[0152] The compound is conveniently administered in unit dosage form; for example, containing 5 to 1000 mg, conveniently 10 to 750 mg, most conveniently, 50 to 500 mg of active ingredient per unit dosage form.
[0153] Ideally, the active ingredient should be administered to achieve peak plasma concentrations of the active compound of from about 0.5 to about 75 μM, preferably, about 1 to 50 μM, most preferably, about 2 to about 30 μM. This may be achieved, for example, by the intravenous injection of a 0.05 to 5% solution of the active ingredient, optionally in saline, or orally administered as a bolus containing about 1-100 mg of the active ingredient. Desirable blood levels may be maintained by continuous infusion to provide about 0.01-5.0 mg/kg/hr or by intermittent infusions containing about 0.4-15 mg/kg of the active ingredient(s).
[0154] The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example, as two, three, four or more sub-doses per day. The sub-dose itself may be further divided, e.g., into a number of discrete loosely spaced administrations; such as multiple inhalations from an insufflator or by application of a plurality of drops into the eye.
[0155] The ability of a compound of the invention to act as an MMP inhibitor may be determined using pharmacological models which are well known to the art, or using the methods described hereinbelow.
[0156] Fluorescence Enzymatic Activity Assays
[0157] The enzymatic activity of MMP-2, MMP-9, and MMP-7 was monitored with the fluorescence quenched substrate MOCAcPLGLA 2 pr(Dnp)-AR-NH 2 . Fluorescence was measured with a Photon Technology International (PTI) spectrofluorometer interfaced to a Pentium computer, equipped with the RatioMaster™ and FeliX™ hardware and software, respectively. The cuvette compartment was thermostated at 25.0° C. Substrate hydrolysis was monitored at emission and excitation wavelengths of 328 and 393 nm and excitation and emission band passes of 1 and 3 nm, respectively. Fluorescence measurements were taken every 4 s. Less than 10% hydrolysis of the fluorogenic substrate was monitored, as described by Knight. Knight, C. G. Methods Enzymol. 1995, 248, 18-34. Stromelysin 1 enzymatic activity was monitored using the synthetic fluorogenic substrate MOCAcRPKPVE-Nva-WRK(Dnp)-NH 2 (Peptides International, Louisville, Ky.) at excitation and emission wavelengths of 325 and 393 nm and excitation and emission band passes of 1 and 3 nm, respectively.
[0158] Enzymes and Protein Inhibitors.
[0159] Human pro-MMP-2, pro-MMP-9, TIMP-1 and TIMP-2 were expressed in HeLa S3 cells infected with the appropriate recombinant vaccinia viruses and were purified to homogeneity, as previously described. Fridman, R.; Fuerst, T. R.; Bird, R. E.; Hoyhtya, M.; Oelkuct, M.; Kraus, S.; Komarek, D.; Liotta, L. A.; Berman, M. L.; Stetler-Stevenson, W. G. J. Biol. Chem. 1992, 267, 15398-15405. Fridman, R.; Birs, R. E.; Hoyhtya, M.; Oelkuct, M.; Komarek, D.; Liang, C. M.; Berman, M. L.; Liotta, L. A.; Stetler-Stevenson, W. G.,; Fuerst, T. R. Biochem. J. 1993, 289, 411-416. Pro-MMP-2, pro-MMP-9, TIMP-1 and TIMP-2 concentrations were determined using the extinction coefficients of 122,800, 114,360, 26,500 and 39,600 M −1 cm −1 , respectively. To obtain active MMP-2, pro-MMP-2 (7.3 μM) was incubated at 37° C. for 1 h with 1 mM p-aminophenylmercuric acetate (APMA) (dissolved in 200 mM Tris) in buffer C. The enzyme solution was dialyzed against buffer D at 4° C. to remove APMA. Active MMP-9 was obtained by incubating pro-MMP-9 (1 μM) with heat-activated recombinant human stromelysin 1 (68 nM) (MMP-3, generously provided by Dr. Paul Cannon, Center for Bone and Joint Research, Palo Alto, Calif.) at 37° C., for 2.5 h in buffer C.
[0160] The resulting solution was subjected to gelatin-agarose chromatography to remove stromelysin 1. MMP-9 was eluted with buffer D containing 10% DMSO and dialyzed against the same buffer without DMSO to remove the organic solvent. Pro-MMP-2 and pro-MMP-9 activation reactions were monitored using the fluorescence quenched substrate MOCAcPLGLA 2 pr(Dnp)-AR-NH 2 (Peptides International, Louisville, Ky.), as will be described below. The MMP-2 and MMP-9 concentrations were determined by titration with TIMP-1.
[0161] Kinetic Analyses.
[0162] Progress curves were obtained by adding enzyme (0.5-2 nM) to a mixture of fluorogenic substrate (5-7 μM) and varying concentrations of inhibitor in buffer R containing 5-15% DMSO (final volume 2 ml), in acrylic cuvettes with stirring and monitoring the increase in fluorescence with time for 15-30 minutes. The progress curves were nonlinear least squares fitted to Equation 1 (Muller-Steffner, H. M., Malver, O., Hosie, L., Oppenheimer, N. J., and Schuber, F. J. Biol. Chem. 1992, 267, 9606-9611.):
F=v s t+I ( v o −v s )(1 −exp (− kt ))/ k+F 0 (1)
[0163] where v o represents the initial rate, v s , the steady state rate, k, the apparent first order rate constant characterizing the formation of the steady-state enzyme-inhibitor complex and F o , the initial fluorescence, using the program SCIENTIST (MicroMath Scientific Software, Salt Lake City, Utah). The obtained k values, v 0 and v s were further analyzed according to Equations 2 and 3 for a one-step association mechanism
k=k off +k on [I ]/(1 +[S]/Km ) (2)
(v o −v s )/v s =[I ]/( K i (1 +[S]/K m )) (3)
[0164] Intercept and slope values, obtained by linear regression of the k versus inhibitor concentration plot (Equation 2), yielded the association and dissociation rate constants k on and k off , respectively, and the inhibition constant K i (k off /k on ). Alternatively, K i was determined from the slope of the (v o −v s )/v s vs [I] plot according to Equation 3.
[0165] The dissociation rate constants were determined independently from the enzyme activity recovered after dilution of a pre-formed enzyme-inhibitor complex. To this end, typically 200 nM of enzyme was incubated with 1 μM of inhibitor for a sufficient time to reach equilibrium (>45 min) at 25.0° C. The complex was diluted into 2 mL of buffer R containing fluorogenic substrate (5-7 μM final concentration) to a final enzyme concentration of 1 nM. Recovery of enzyme activity was monitored for ˜30 min. The fluorescence versus time trace was fitted, using the program SCIENTIST, to Equation 4
F=v s t +( v o −v s )(1 −exp (− k off ))/ k off +F 0 (4)
[0166] where v o represents the initial rate (very small), v s , the rate observed when the E.I complex is completely dissociated and k off , the first order rate constant when the E.I dissociation.
[0167] Analysis for linear competitive inhibition was performed in the following manner. Initial rates were obtained by adding enzyme (0.5-2 nM) to a mixture of fluorogenic substrate (5-7 μM) and varying concentrations of inhibitor in buffer R, containing 5-15% DMSO (final volume 1 mL) in semi-micro quartz cuvettes, and monitoring the increase in fluorescence with time for 5-10 minutes. The fluorescence versus time traces were fitted by linear regression analysis using FeliX™. The initial rates were fitted to Equation 5 (Segel, I. H. in: Enzyme Kinetics , Wiley Inc., New York, 1975, pp. 104.):
v/V max =S /( K m (1 +I/K i )+ S ) (5)
[0168] where v and V max represent the initial and maximal velocities, S and I, the substrate and inhibitor concentrations, respectively, K m the Michaelis-Menten constant for the substrate-enzyme reaction and K i the inhibition constant, using the program SCIENTIST.
[0169] Inhibitors 1-4 all bind with the active site of the MMPs that were used in the study, with K i values of micromolar, or less, however, the behavior of inhibitor 1 was very different. Inhibitor 1 showed a dual behavior. It served as a mechanism-based inhibitor with a partition ratio of 79±10 (i.e. k cat /k inact ) for MMP-2 and 416±63 for MMP-9. Furthermore, it also behaved as a slow-binding inhibitor, for which the rate constants for the on-set of inhibition (k on ) and recovery of activity from inhibition (k off ) were evaluated (Table 1). It would appear that coordination of the thiirane with the zinc ion (as seen in energy-minimized computational models; FIG. 1) would set in motion a confornational change, which is presumed from the slow-binding kinetic behavior. The kinetic data fit the model for slow-binding inhibition. Morrison, J. F. Adv. Enzymol. 1988, 61, 201-301. Covalent modification of the enzymes results from this conformational change. Inhibitor 1 was incubated with MMP-2 to the point that less than 5% activity remained. This inhibitor-enzyme complex was dialyzed over three days, which resulted in recovery of approximately 50% of the activity. This observation is consistent with modification of the active site Glu-404 (according to the numbering for human MMP-2), via the formation of an ester bond, which is a relatively labile covalent linkage. The time-dependent loss of activity is not merely due to the slow-binding behavior. For instance, for a k off of 2×10 −3 s −1 (the values are not very different from one another in Table 1) the half time for recovery of activity (t ½ ) is calculated at just under 6 min. The fact that 50% of activity still did not recover after dialysis over three days strongly argues for the covalency of enzyme modification.
[0170] Selectivity in inhibition of gelatinases by inhibitor 1 was observed. Its K i values are 13.9±4 nM and 600±200 nM for MMP-2 and MMP-9, respectively. The corresponding K i values are elevated to the micromolar range for the other MMPs, even for the case of MMP-3, which does show the slow-binding, mechanism-based inhibition profile. In addition, the values for k on are 611- and 78-fold larger for MMP-2 and MMP-9, respectively, than that for MMP-3. Whereas the k off values are more similar to one another, the value for MMP-2 is the smallest, so the reversal of inhibition of this enzyme takes place more slowly. Collectively, these kinetic parameters demonstrate that inhibitor 1 can be a potent and selective inhibitor for MMP-2, MMP-9, and especially MMP-2. It has been previously shown that two molecules of either TIMP-1 or TIMP-2 (endogenous cellular protein inhibitors of MMPs) bind to activated MMP-2 and MMP-9. Olson, M. W.; Gervasi, D. C.; Mobashery, S.; Fridman, R. J. Biol. Chem. 1997, 272, 29975. One binding event is high affinity and would appear physiologically relevant, whereas the second binding event takes place with relatively lower affinity (micromolar). Olson, M. W.; Gervasi, D. C.; Mobashery, S.; Fridman, R. J. Biol. Chem. 1997, 272, 29975. Inhibition of MMP-2 and MMP-9 by TIMPs also follows slow-binding kinetics. The kinetic parameters for these interactions at the high affinity site are listed in Table 1. The kinetic parameters for the slow-binding component of inhibition of MMP-2 and MMP-9 by inhibitor 1 (K on and K off ) approach closely the same parameters for those of the protein inhibitors. Olson, M. W.; Gervasi, D. C.; Mobashery, S.; Fridman, R. J. Biol. Chem. 1997, 272, 29975-29983.
[0171] Oxiranes 4-6 inhibit MMPs in a competitive manner with higher K i values. There was no evidence of slow-binding behavior or time-dependence of loss of activity with this inhibitor with any of the MMPs.
[0172] Small-molecule inhibitor 1 follows both slow-binding and mechanism-based inhibition in its kinetic profile. This compound appears to behave very similarly to the endogenous cellular protein inhibitors for MMPs (TIMPs) in the slow-binding component of inhibition. Furthermore, the inhibitor also exhibits a covalent mechanism-based behavior in inhibition of these enzymes. The high discrimination in targeting that inhibitor 1 displays (both in affinities and the modes of inhibition) among the other structurally similar MMPs is noteworthy and could serve as a paradigm in the design of inhibitors for other closely related enzymes in the future.
EXAMPLES
[0173] Experimental Procedures
[0174] [0174] 1 H and 13 C NMR spectra were recorded on either a Varian Gemini-300, a Varian Mercury-400 or a Varian Unity-500 spectrometer. Chemical shifts are reported in ppm from tetramethylsilane on the δ scale. Infrared spectra were recorded on a Nicolet 680 DSP spectrophotometer. Mass spectra were recorded on a Kratos MS 8ORFT spectrometer. Melting points were taken on an Electrothermal melting point apparatus and are uncorrected. Thin-layer chromatography was performed with Whatman reagents 0.25 mm silica gel 60-F plates. All other reagents were purchased from either Aldrich Chemical Company or Across Organics.
[0175] The following buffers were used in experiments with enzymes: Buffer C (50 mM HEPES at pH 7.5, 150 mM NaCl, 5 mM CaCl 2 , 0.02% Brij-35); buffer R (50 mM HEPES at pH 7.5, 150 mM NaCl, 5 mM CaCl 2 , 0.01% Brij-35, and 1% v/v Me 2 SO) and buffer D (50 mM Tris at pH 7.5, 150 mM NaCl, 5 mM CaCl 2 , and 0.02% Brij-35).
Example 1
[0176] (4-Phenoxyphenylsulfonyl)methyloxirane (4).
[0177] To compound 11 (598 mg, 2.5 mmol) in dichloromethane (10 mL), mCPBA (2.84 g, 10 mmol, Aldrich 57-86%), was slowly added. The mixture was stirred at room temperature for 3 days, after which time a second portion of mCPBA (2.84 g, 10 mmol) was added. The mixture was then stirred for another 4 days, after which time the mixture was poured into ethyl acetate (200 mL), and washed with aqueous sodium thiosulfate (3×50 mL, 10% w/v), aqueous sodium bicarbonate (3×50 ml, 5% w/v), and brine (50 ml). The organic phase was dried over magnesium sulfate and was concentrated to provide a yellow oil. The crude material was purified by column chromatography (silica, 4:1 hexanes:ethyl acetate) to give compound 4 as a pale yellow semi-solid (501 mg, 70%). 1 H NMR (500 MHz, CDCl 3 ) δ 7.90-7.86 (m, 2H), 7.46-7.40 (m, 2H), 7.26-7.22 (m, 1H), 7.10-6.96 (m, 4H), 3.34-3.24 (m, 2H), 2.84-2.80 (m, 1H), 2.49-2.46 (m, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 163.15, 154.95, 130.76, 130.51, 125.52, 120.77, 117.83, 59.89, 46.13; IR(film) 3054 (w), 2919 (w), 1576 (s), 1492 (s), 1320 (s), 1245 (s), 1148 (s) cm −1 ; m/z (EI) 290 (M + , 100%), 233 (70), 217 (50), 185 (40); HRMS (EI) calcd. for C 15 H 14 O 4 S 290.0613, found 290.0611.
[0178] The intermediate, compound 11, was prepared as follows:
[0179] (A.) O-4-Phenoxyphenyl-N,N-dimethylthiocarbamate (8).
[0180] To a solution of 4-phenoxyphenol (7, 8.46 g, 45 mmol) in DMF (40 mL) at 10° C., sodium hydride (1.83 g, 45 mmol, 60% dispersion in mineral oil) was added in small portions. After the evolution of hydrogen ceased, N,N-dimethylthiocarbamoyl chloride (6.16 g, 50 mmol) was added in one portion. The reaction mixture was then stirred at 70° C. for 2 hours. The mixture was cooled to room temperature, poured into water (100 mL) and extracted with chloroform (3×50 mL). The combined organic extracts were washed with aqueous potassium hydroxide (50 mL, 5% w/v), and brine (10×50 mL). The organic extract was dried over magnesium sulfate and concentrated to obtain a yellow oil. The crude material was purified by column chromatography (silica, 5:1 hexanes:ethyl acetate) to give compound 8 as a white solid (11.16 g, 90%). m.p. 50-51° C.; 1 H NMR (300 MHz, CDCl 3 ) δ 7.38-7.31 (m, 2H), 7.14-7.08 (m, 1H), 7.06-7.00 (m, 6H), 3.46 (s, 3H), 3.34 (s, 3H); 13 C NMR (75 MHz, CDCl 3 ) δ 188.17, 157.26, 155.16, 149.62, 130.05, 124.11, 123.71, 119.31, 43.57, 38.96; IR (KBr) 3040 (m), 2938 (s), 1587 (s), 1487 (s), 1394 (s), 1287 (s), 1190 (s) cm −1 ; m/z (EI) 273 (M + , 15%), 186 (100); HRMS (EI) calcd. for C 15 H, 5 NO 2 S 273.0823, found 273.0824.
[0181] (B.) S-4-Phenoxyphenyl-N,N-dimethylthiocarbamate (9).
[0182] Compound 8 (3.99 g, 15 mmol) was heated under argon at 260° C. for 3.5 hours. The resulting dark brown oil was purified by column chromatography using a gradient eluent system (silica, 19:1 then 9:1 then 3:1 hexanes:ethyl acetate) to obtain compound 9 as a pale yellow solid (2.55 g, 64%). m.p. 97-99° C.; 1 H NMR (400 MHz, CDCl 3 ) δ 7.45-7.40 (m, 2H), 7.40-7.30 (m, 2H), 7.15-7.10 (m, 1H), 7.05 (d, J=8.8 Hz, 2H) 6.98 (d, J=8.8 Hz, 2H) 3.08 (bs, 3H), 3.02 (bs, 3H); 13 C NMR (100 MHz, CDCl 3 ) δ 167.48, 158.87, 156.53, 137.66, 130.09, 124.14, 122.39, 119.87, 118.94,37.14; IR(KBr) 3037 (w), 2925 (w), 1652 (s), 1581 (s) 1486 (s), 1239 (s) cm −1 ; m/z (EI) 273 (M + , 25%), 257 (5), 200 (5); HRMS (EI) calcd. for C 15 H 15 NO 2 S 273.0823, found 273.0822.
[0183] (C.) 4-Phenoxythiophenol (10).
[0184] A mixture of compound 9 (2.55 g, 9 mmol) in methanol (20 mL), and aqueous NaOH (10 mL, 10% w/v), were refluxed for 4 hours. The solution was cooled to room temperature and was acidified to pH 1 with aqueous HCl (1M). Water (100 mL) was added and the mixture was extracted with chloroform (3×50 mL). The combined organic extracts were washed with brine (50 mL), dried over magnesium sulfate and concentrated to obtain a yellow oil. The crude product was purified by column chromatography (silica, 5:1 hexanes:ethyl acetate) to give compound 10 as a pale yellow oil (1.80 g, >99%). 1H NMR (300 MHz, CDCl 3 ) δ 7.36-7.31 (m, 2H), 7.30-7.25 (m, 2H), 7.13-7.09 (m, 1H), 7.04-6.88 (m, 4H), 3.43 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 157.30, 156.15, 132.14, 130.00, 124.04, 123.95, 119.88, 119.04; IR(film) 3038 (w), 1583 (s), 1484 (s), 1236 (s), 1166 (s) cm −1 ; m/z (EI) 202 (M + , 100%; HRMS (EI) calcd. for C 12 H 10 OS 202.0452, found 202.0454.
[0185] (D.) 3-(4-Phenoxyphenylsulfanyl)-1-propene (11).
[0186] To a mixture of compound 10 (516 mg, 2.7 mmol) and potassium carbonate (534 mg, 3.9 mmol) in DMF (5 mL), allyl bromide (253 μL, 2.9 mmol) was added in one portion. The mixture was stirred at room temperature overnight. The crude reaction mixture was poured into ether (200 mL), washed with saturated aqueous potassium carbonate (25 mL), and brine (6×50 mL). The organic layer was dried over magnesium sulfate and concentrated in vacuo to give a yellow oil. The crude material was purified by column chromatography ,(silica, 98:2 hexanes:ethyl acetate) to obtain the title compound as a pale yellow oil (598 mg, 93%). 1 H NMR (300 MHz, CDCl 3 ) δ 7.38-7.32 (m, 4H), 7.15-7.10 (m, 1H), 7.04-7.00 (m, 2H), 6.97-6.92 (m, 2H), 5.92-5.82 (m, 1H), 5.10-5.04 (m, 2H), 3.50 (d, J=7.2 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 157.14, 156.73, 134.01, 133.22, 130.05, 129.50, 123.75, 119.40, 119.25, 117.81, 38.84; IR(film) 3078 (w), 3039 (w), 1582 (s), 1484 (s), 1240 (s), 1165 (s) cm −1 ; m/z (EI) 242 (M+, 100%), 201 ([M-allyl] + , 100); HRMS (EI) calcd. for C 15 H 14 OS 242.0765, found 242.0764.
Example 2
[0187] 2-(4-Phenoxyphenylsulfonyl)ethyloxirane (5).
[0188] The title compound was prepared in the same manner as described for 4, with the exception that compound 12 was used in place of compound 11, and the reaction time was 2 days. The title compound was obtained as a white solid (78%). m.p. 75-77° C.; 1 H NMR (500 MHz, CDCl 3 ) δ 7.84-7.80 (m, 2H), 7.44-7.38 (m, 2H), 7.24-7.20 (m, 1H), 7.09-7.04 (m, 4H), 3.25-3.15 (m, 2H), 3.02-2.97 (m, 1H), 2.76 (t, J=4.3 Hz, 1H), 2.49 (dd, J=3.0 and 5.0 Hz, 1H), 2.19-2.10 (m, 1H), 1.86 (m, 1H); 3 C NMR (125 MHz, CDCl 3 ) δ 162.93, 155.02, 130.58, 130.81, 125.47, 120.69, 117.91, 53.15, 50.32, 47.29, 26.23; IR(KBr disc) 3040 (s), 1580 (s), 1490 (s), 1320 (s), 1248 (s), 1148 cm −1 ; m/z (EI) 304 (M + , 80%), 233 (50), 217 (100); HRMS (EI) calcd. for C 16 H 16 O 4 S 304.0769, found 304.0768.
[0189] (A.) 4-(4-Phenoxyphenylsulfanyl)-1-butene (12).
[0190] The title compound was prepared in the same manner as described for 11, with the exception that 4-bromo-1-butene was used in place of allyl bromide. Compound 12 was obtained as a colorless oil (88%). 1 H NMR (400 MHz, CDCl 3 ) δ 7.37-7.32 (m, 4H), 7.14-7.10 (m, 1H), 7.04-7.00 (m, 2H), 6.96-6.88 (m, 2H), 5.90-5.80 (m, 1H), 5.12-5.02 (m, 2H), 2.98 (m, 2H), 2.41-2.34 (m, 2H); 13 C NMR (100 MHz, CDCl 3 ) δ 157.18, 156.50, 136.65, 132.57, 130.05, 123.72, 119.55, 119.21, 116.47, 34.65, 33.71; IR(film) 3076 (w), 2923 (w), 1583 (s), 1485 (s), 1239 (s) cm −1 ; m/z (EI) 256 (M + , 100%), 215 ([M-allyl] + , 90), 202 (15); HRMS (EI) calcd. for C 16 H 16 OS 256.0922found 256.0922.
Example 3
[0191] 3-(4-Phenoxyphenylsulfonyl)propyloxirane (6).
[0192] The title compound was prepared in the same manner as described for 4, with the exception that compound 13 was used in place of compound 11, and that the reaction time was 3 days. The title compound was obtained as a white solid (94%). 1 H NMR (500 MHz, CDCl 3 ) δ7.86-7.80 (m, 2H), 7.44-7.39 (m, 2H), 7.25-7.22 (m, 1H), 7.10-7.04 (m, 4H), 3.21-3.08 (m, 2H), 2.90-2.86 (m, 1H), 2.74 (t, J=4.5 Hz, 1H), 2.45 (dd, J=2.5 and 4.5 Hz, 1H), 1.92 (quin, J=7.0 Hz, 2H), 1.85-1.78 (m, 1H), (m, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 162.84, 155.08, 130.58, 130.48, 125.43, 120.70, 117.88, 56.28, 51.64, 46.86, 31.17, 20.12; IR(KBr disc) 3063 (w), 2923 (w), 1582 (s), 1488 (s), 1294 (s), 1246 (s), 1142 (s) cm −1 ; m/z (EI) 318 (M + , 40%), 290 (20), 217 (100%); HRMS (EI) calcd. for C 17 H 18 O 4 S 318.0926, found 318.0924.
[0193] (A.) 5-(4-Phenoxyphenylsulfanyl)-1-pentene (13).
[0194] The title compound was prepared in the same manner as described for 11, with the exception that 5-bromo-1-pentene was used in place of allyl bromide. The title compound was obtained as a colorless oil (65%). 1 H NMR (500 MHz, CDCl 3 ) δ 7.37-7.34 (m, 4H), 7.13-7.09 (m, 1H), 7.03-7.00 (m, 2H), 6.96-93 (m, 2H), 5.83-5.74 (m, 1H), 5.06-4.98 (m, 2H), 2.88 (t, J=7.0 Hz, 2H), 2.22-2.16 (m, 2H), 1.73 (q, J=7.0 Hz, 2H); 13 C NMR (125 MHz, CDCl 3 ) δ 157.23, 156.36, 137.84, 132.30, 130.41, 130.03, 123.67, 11 9.55, 119.16, 115.62, 34.61, 32.86, 28.6 1; IR(film) 3075 (w), 2929 (m), 1583 (s), 1484 (s), 1236 (s) cm −1 ; m/z (EI) 270 (M + , 100%), 215 (70), 202 (60); HRMS (EI) calcd. for C 17 H 18 OS 270.1078, found 270.1076.
Example 4
[0195] (4-Phenoxyphenylsulfonyl)methylthiirane (1).
[0196] To a solution of compound 4 (710 mg, 2.5 mmol) in THF (5 mL), a solution of ammonium thiocyanate (559 mg, 7.4 mmol) in water (3 mL) was added. The reaction was stirred at room temperature for 16 hours, after which time it was poured into ethyl acetate (100 mL), and then washed with water (25 mL), followed by brine (25 mL). The organic phase was dried over magnesium sulfate and was concentrated to give a white oil. The crude material was purified by column chromatography (silica, 8:1 hexanes:ethyl acetate) to obtain compound 1 as a white solid (102 mg, 14%). m.p. 99-101° C.; 1 H NMR (500 MHz, CDCl 3 ) δ 7.89-7.84 (m, 2H), 7.46-7.40 (m, 2H), 7.26-7.22 (m, 1H), 7.11-6.96 (m, 4H), 3.52 (dd, J=5.5 and 14.5 Hz, 1H), 3.17 (dd, J=7.5 and 14.5 Hz, 1H), 3.09-3.03 (m, 1H), 2.53 (dd, J=2.0 and 6.0 Hz, 1H) 2.16 (dd, J=2.0 and 5.0 Hz, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 163.20, 155.02, 132.13, 130.95, 130.52, 125.52, 120.69, 117.97, 62.90, 26.31, 24.47; IR(KBr disc) 3030 (w), 1583 (s), 1486 (s), 1317 (s), 1246 (s), 1141 (s) cm −1 ; m/z (EI) 306 (M + , 2%), 242 ([M-SO 2 ] + , 35); HRMS (EI) calcd. for C 15 H 14 O 3 S 2 306.0384, found 306.0382.
Example 5
[0197] 2-(4-Phenoxyphenylsulfonyl)ethylthiirane (2).
[0198] The title compound was prepared in the same manner as described for 1, with the exception that compound 5 was used in place of compound 4. The crude material was purified by column chromatography (silica, 2:1 hexanes:ethyl acetate) to give the title compound as a white solid (93%). m.p. 99-101° C.; 1 H NMR (500 MHz, CDCl 3 ) 8 7.83 (d, J=8.0 Hz, 2H), 7.42 (t, J=8.0 Hz, 2H), 7.26-7.22 (m, 1H), 7.10-7.06 (m, 4H), 3.30-3-20 (m, 2H), 2.98-2.92 (m, 1H), 2.52 (dd, J=1 and 6 Hz, 1H), 2.48-2.39 (m, 1H), 2.18 (dd, J=1 and 5 Hz, 1H), 1.78-1.69 (m, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 162.94, 155.03, 132.50, 130.55, 130.51, 125.48, 120.71, 117.92, 55.97, 33.62, 29.82, 26.05; IR(KBr disc) 3040 (w), 1583 (s), 1487 (s), 1256 (s), 1142 (s) cm −1 ; m/z (EI) 320 (M + , 50%), 288,(20), 234 (40), 217 (60), 170 (100); HRMS (EI) calcd. for C 16 H 16 O 3 S 2 320.0541, found 320.0540.
Example 6
[0199] 3-(4-Phenoxyphenylsulfonyl)propylthiirane (3).
[0200] The title compound was prepared in the same manner as described for 1, with the exception that compound 6 was used in place of compound 4. The crude material was purified by column chromatography (silica, 2:1 hexanes:ethyl acetate) to give the title compound as a white solid (85%). m.p. 75-76° C.; 1 H NMR (500 MHz, CDCl 3 ) δ 7.85-7.82 (m, 2H), 7.44-7.40 (m, 2H), 7.26-7.22 (m, 1H), 7.10-7.06 (m, 4H), 3.20-3.09 (m, 2H), 2.84-2.79 (m, 1H), 2.50 (dd, J=1 and 6 Hz, 1H), 2.14 (dd, J=1 and 5.5 Hz, 1H), 2.12-2.06 (m, 1H), 1.97 (quin, J=8 Hz, 2H), 1.45-1.38 (m, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 162.85, 155.08, 132.55, 130.60, 130.49, 125.43, 120.69, 117.91, 56.09, 35.13, 34.86, 25.72, 22.92; IR(KBr disc) 3000 (w), 1583 (s), 1480 (s), 1254 (s), 1143 (s) cm −1 ; m/z (EI) 334 (M + , 30%), 301 (10), 234 (100), 217 (70), 170 (70); HRMS (EI) calcd. for C 17 H 18 O 3 S 2 334.0697, found 334.06.
Example 7
[0201] [0201] TABLE 1 Kinetics parameters for inhibition of MMPs by compounds of the present invention k on (M −1 s −1 ) × 10 −4 k off (s −1 ) × 10 3 K i (μM) Compound 1 MMP-2 11 ± 1 1.5 ± 0.6a 0.0139 ± 0.0004 1.8 ± 0.1 MMP-9 1.4 ± 0.3 9 ± 1 a 0.6 ± 0.2 7.1 ± 0.5 MMP-3 (1.8 ± 0.4) ± 10 −2 2.7 ± 0.9 a 15 ± 6 5.5 ± 0.4 MMP-7 96 ± 41 Compound 2 MMP-2 4.7 ± 0.7 MMP-9 44 ± 5 MMP-3 NI b MMP-7 NI MMP-1 NI Compound 3 MMP-2 4.3 ± 0.7 MMP-9 181 ± 41 MMP-3 NI MMP-7 NI MMP-1 NI Compound 4 MMP-2 25 ± 2 MMP-9 186 ± 11 MMP-3 NI MMP-7 NI MMP-1 NI TIMP-1 c MMP-2 4.4 ± 0.1 1.3 ± 0.2 0.029 ± 0.005 MMP-9 5.2 ± 0.1 1.2 ± 0.2 0.024 ± 0.004 TIMP-2 c MMP-2 3.3 ± 0.1 0.8 ± 0.1 0.023 ± 0.004 MMP-9 2.2 ± 0.1 1.3 ± 0.2 0.058 ± 0.007 Compound 5 MMP-2 5.1 ± 0.5 MMP-9 102 ± 2 MMP-3 NI a MMP-7 NI MMP-1 NI Compound 6 MMP-2 10.7 ± 0.6 MMP-9 75 ± 6 MMP-3 NI b MMP-7 NI MMP-1 NI
[0202] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. In addition, some references were obtained on the world wide web (www). These references are also incorporated by reference herein, as though individually incorporated by reference.
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The invention provides compounds that inhibit MMPs; methods for treating or preventing cancer, angiogenesis, arthritis, connective tissue disease, cardiovascular disease, inflammation or autoimmune disease in a mammal; a method for inhibiting a matrix metalloproteinase in vivo or in vitro; and a method for imaging a tumor in vivo or in vitro.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates generally to pneumatic tires and devices that are adhered to pneumatic tires to monitor the conditions of the tires. More particularly, the present invention is related to the connection of the monitoring device to the tire. Specifically, the present invention relates to the method of attaching and the attachment of a monitoring device to the inner surface of a pneumatic tire using a surface preparation and an adhesive.
2. Background Information
It is desired in the art to monitor the conditions of tires while they are installed and in use on a particular vehicle. It is particularly desirable to measure tire wear, internal temperature, and internal pressure. Other desirable measurements may be the number of tire rotations that have occurred in given time. These measurements are preferably capable of being taken while the tire is in use without having to remove the tire from the vehicle or otherwise interrupt the use of the vehicle to take the measurements. It is particularly desirable to monitor the conditions and statistics on large off-the-road truck tires because the off-the-road tires are expensive and subject to harsher conditions than typical passenger car tires. The off-the-road tires on large trucks and other vehicles also must be regularly maintained to maximize vehicle efficiency. It is also desirable to monitor the tires of certain on road trucks and buses.
Numerous types of such monitoring devices are known in the art. One type of known monitoring device uses a passive integrated circuit embedded within the body of the tire that is activated by a radio frequency transmission that energizes the circuit by inductive magnetic coupling. Other prior art devices used for monitoring tire conditions include self-powered circuits that are positioned external of the tire, such as at the valve stem. Other active, self-powered programmable electronic devices are disclosed in U.S. Pat. Nos. 5,500,065, 5,573,610, 5,562,787, and 5,573,611 which are assigned to the assignee of the present application.
One problem common to each of these monitoring devices is the problem of attaching the monitoring device to the tire. The attachment problem is difficult when the monitoring device is attached to the inside surface of the tire, the outside surface of the tire, or imbedded within the body of the tire. The attachment problem is difficult because the forces on the electronic device are significant and numerous. Tires not only are subjected to rotational forces when the vehicle is moving but also are subjected to various impact forces when the tire contacts bumps or surface irregularities. The attachment of the monitoring device to the tire must be strong enough and secure enough to maintain the position of the monitoring device with respect to the tire while experiencing all of these forces while also protecting the monitoring device from damage resulting from these forces.
Another problem with the attachment of a monitoring device to a tire is that the tire must be balanced about its rotational axis to efficiently perform. The monitoring device itself already adds weight to the tire that may require the tire to be counterbalanced. It is thus desired to minimize the weight of the attachment so that additional counterbalancing weights do not have to be added to the tire. It is thus desired to provide an attachment that is strong and secure while being small and lightweight.
Another problem experienced with attaching a monitoring device to a pneumatic tire is that the surface where the monitoring device is being anchored is often not stable. Tires are designed to flex and stretch to accommodate various pressures and forces. The attachment of the monitoring device to the tire must accommodate the movement and stretching of the tire surface where the monitoring device is connected. Such accommodation must last throughout the life of the tire and function at a wide range of temperatures and pressures. In the patents listed above, the monitoring devices are held in a pocket that is formed with a piece of material connected to the innerliner of the tire. Although these pockets function for their intended purposes, the construction of the pockets increases the counterbalancing problem and increase the complexity of the assembly steps.
A further problem experienced in connecting a monitoring device to a pneumatic tire is that tires are manufactured on automated assembly lines. The attachment method must be able to be relatively easily engineered into the existing automated tire assembly lines to be useful. As such, the method of attaching the monitoring device to the pneumatic tire should minimize any manual steps or steps that require precise component manipulation.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an objective of the present invention to provide an attachment that may be used to connect a monitoring device to the inner surface of a pneumatic tire that overcomes each of the problems experienced in the art.
Another objective of the present invention is to provide an attachment that maintains the connection between the monitoring device and the tire when the tire experiences predictable rotational and shock forces.
Still another objective of the present invention is to provide an attachment for connecting a monitoring device to a pneumatic tire that is lightweight so that the tire does not have to be excessively counterbalanced.
Yet another objective of the present invention is to provide an attachment for connecting a monitoring device to the interior of a pneumatic tire that accommodates the stretching and movement of the inner surface of the pneumatic tire.
A further objective of the present invention is to provide a method for attaching a monitoring device to the interior surface of a pneumatic tire that is easy to perform and may be performed by automated machinery in a tire manufacturing line.
A further objective of the present invention is to provide a method for attaching a monitoring device to the inner surface of a pneumatic tire that may be used at a variety of locations inside the pneumatic tire.
A further objective of the present invention is to provide a method for attaching a monitoring device to the inner surface of a pneumatic tire that does not require additional structural elements to be inserted into the tire or attached to the tire to secure the monitoring device.
An additional objective of the present invention is to provide an attachment and method for attaching a monitoring device to the interior surface of a pneumatic tire that is of simple construction, that achieves the stated objectives in a simple, effective, and inexpensive manner, that solves the problems, and that satisfies the needs existing in the art.
These and other objectives and advantages of the present invention are achieved by an attachment that includes an adhesive characterized by high viscosity at room temperature and capable of curing at 100° C. and lower, the adhesive adhering a monitoring device to the innerliner of a pneumatic article where the innerliner is at least 0.06 inch thick.
Other objectives of the present invention are achieved by a method for adhering a monitoring device to a tire including the steps of selecting a portion of the innerliner of the tire where the monitoring device will be connected; roughening the selected portion of the innerliner; applying an adhesive to at least one of the monitoring device and roughened portion; placing a monitoring device on the roughened portion of the innerliner; and curing the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention, illustrative of the best mode in which Applicants contemplated applying the principles of the invention, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a sectional view of a pneumatic tire with a monitoring device attached to the innerliner of the pneumatic tire by the method of the present invention;
FIG. 2 is a perspective view of a monitoring device attached to the innerliner of the pneumatic tire by the method of the present invention;
FIG. 3 is a perspective view of the monitoring device lifted away from the innerliner to show the treatment of the innerliner and the monitoring device according to the concepts of the present invention;
FIG. 4 is a plan view of an unencapsulated monitoring device; and
FIG. 5 is an enlarged sectional view similar to FIG. 1 showing an encapsulated monitoring device attached to the innerliner of a pneumatic tire.
Similar numbers refer to similar elements throughout the specification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A pneumatic article in the nature of a vehicle tire is depicted in the drawings and is indicated generally by the numeral 10 . Tire 10 is of known construction and includes a pair of sidewalls 12 which extend outwardly from a pair of bead rings 14 . A tread package 16 is located at the outer ends of sidewalls 12 . Tire 10 further includes a plurality of cords or belts 18 that provide structural strength to tire 10 . Tire 10 is supported on a rim 20 in a manner that provides an inner chamber 22 between tire 10 and rim 20 . Inner chamber 22 is filled with pressurized air when tire 10 is in use to allow tire 10 to support the weight of the vehicle on which tire 10 is used. The pressurized air in chamber 22 is maintained in tire 10 by an innerliner 24 that is substantially impervious to air. Innerliner 24 is of known construction and includes not only butyl rubber but also chloro-butyl rubber, bromo-butyl rubber, and combinations thereof with up to less than 50% natural rubber. It is known in the tire building art that it is difficult to bond to innerliner 24 .
The body of tire 10 is formed from a flexible and somewhat compliant rubber that flexes and stretches when tire 10 is in use. The movement of tire 10 is also transferred to innerliner 24 complicating the problem of bonding an article to the inner surface 26 of innerliner 24 . The structure of tire 10 results in areas of tire 10 that flex more than other areas of tire 10 . The areas that flex the least are the areas closest to rim 20 . These areas are the low flex areas 28 that extend approximately 25% up sidewalls 12 and in some tire 10 configurations extends up to 50% of the height of sidewall 12 . In most tire 10 configurations, low flex area 28 is 25% of the height of sidewalls 12 .
It is also known in the art that innerliner 24 is formed in different thicknesses for different tires 10 . The thickest innerliners 24 are used on off-the-road tires that are used with large vehicles. The thickness of off-the-road innerliners 24 are typically greater than at least 0.06 inch and are frequently greater than ¼ of an inch. Many truck and bus radial tires have innerliners greater than at least 0.06 inch whereas most passenger tires have an innerliner 24 that is less than 0.06 inch thick.
An objective of the present invention is to provide an attachment 30 that may be used to connect a monitoring device 32 to innerliner 24 of tire 10 in a manner that securely holds monitoring device 32 in position when tire 10 is used throughout the life of tire 10 . Monitoring device 32 may be any of a variety of monitoring devices known in the art. In the embodiment of the invention depicted in the drawings, monitoring device 32 is an active electronic monitoring device that includes a microprocessor 34 , a pressure sensor 36 , and a battery 38 such as shown and described in U.S. Pat. Nos. 5,562,787, 5,573,611, 5,500,065, and 5,573,610, the contents of which are incorporated herein by reference. Each of these elements may be supported on a board or substrate 40 and connected to an antenna 42 . It is desired in the art to encapsulate monitoring device 32 in a structurally stable housing 44 that may be a substantially rigid epoxy. Monitoring device 32 includes a bottom surface 46 that is used to bond monitoring device 32 to inner surface 26 of innerliner 24 .
In accordance with another objective of the present invention, the method of attaching monitoring device 32 to innerliner 24 includes the following steps. A location on innerliner 24 in low flex area 28 is first selected to connect monitoring device 32 . The selected location is first roughened to provide a roughened surface 50 that will accept the adhesive used in the present invention. This roughening may be performed by a buffing tool such as a tungsten carbide tool, sand blasting or by a variety of other known tools. Inner surface 26 of innerliner 24 is roughened by removing about 1 mil of material but preferably about 2 mils to remove the cure skin of innerliner 24 that is formed when tire 10 is cured. Roughened area 50 is then cleaned with an innerliner cleaner or a rubber cleaner such as cleaner fluid order no. 16-480 supplied by Patch Rubber Company a division of Myers Industries, Akron, Ohio. The cleaner may also be any degreasing solvent such as a 1,1,2-trichloroethylene or heptane.
Roughened area 50 is then primed with a positive chlorine compound such as any chlorinated primer. A 3% trichlorotriazinetrione solution in butyl acetate is preferred.
Generally, any conventional rubber primer known to the art and to the literature can be utilized. Heretofore, typically chlorine or chlorine-containing compounds have been utilized to prime rubber. That is, a halogen or preferably a chlorine donor compound is utilized. A preferred rubber primer of the present invention is trichlorotriazinetrione which can be applied to the rubber as by brushing, spraying, etc., desirably in a multiplicity of coats. For example, a 3 percent trichlorotriazinetione solution in butyl acetate can be applied in a plurality of coatings such as three, allowing several minutes, e.g., 5 minutes drying time between coatings. Immediately after application of the last coating, its surface can be wiped off with RYMPLECLOTH® to remove by-products such as oils which migrate to the surface. The rubber surface can then be allowed to dry at ambient temperature for about 10 to 15 minutes.
Other rubber primers include the various N-halohydantoins, the various N-haloamides, the various N-haloimides, and combinations thereof. Examples of various desirable N-halohydantoins include 1,3-dichloro-5,5-dimethyl hydantoin; 1,3-dibromo-5,5-dimethyl hydantoin; 1,3-dichloro-5-methyl-5-isobutyl hydantoin; and 1,3-dichloro-5-methyl-5-hexyl hydantoin. Examples of N-haloamides include N-bromoacetamide and tetrachloroglycoluril. Examples of N-haloimides include N-bromosuccinimide and the various chloro substituted striazinetriones, commonly known as mono-, di-, and trichloroisocyanuric acid. The various mono-, di-, or tri-chloroisocyanuric acids, or combinations thereof are a preferred rubber primer with trichloroisocyanuric acid being especially preferred. A three percent by weight trichloroisocyanuric acid solution in butyl acetate is available from Lord Corporation as Chemlok 7707.
The various N-halohydantoins, N-haloamides, and N-haloimide rubber primers usually exist in solid form. They are readily soluble in polar solvent such as acetone and can be applied in liquid form. Application of these rubber primers generally occur at ambient temperatures. Application can be in any conventional manner as through brushing, spraying, and the like. A typical amount of the N-halohydantoins, N-haloamides, and N-haloimide primer in the solvent, for example, ethyl acetate or acetone, is generally from about 0.1 to about 10 percent by weight based upon the total weight of said rubber primer and solvent, and preferably is from about 0.5 percent to about 5 percent. Of course, higher or lower concentrations can be utilized. This solvent system has been found to dry within a matter of minutes so that the adhesive can be applied shortly thereafter. It is thought that the rubber primer adds halogen groups, for example, chlorine to the cured rubber bead which activates the surface thereof, allowing the adhesive to adhere strongly to the cured rubber surface. Still additional rubber primers include various acetamides such as chloroacetamide, bromoacetamide, iodoacetamide, and the like. The thickness of the rubber primer layer can vary greatly and often is thin since it reacts with the rubber.
The primer 48 is allowed to dry thoroughly on area 50 before monitoring device 32 is bonded to innerliner 24 . Bottom surface 46 of monitoring device 32 is then degreased using acetone on a purified cheesecloth such as RYMPLECLOTH® brand, sold by American Fiber and Finishing, Inc. of Westford, Mass., and may also be textured to increase its surface area and ability to bond.
Monitoring device 32 is then bonded to area 50 using a suitable adhesive 52 . A preferred adhesive 52 is an epoxy adhesive such as the FUSOR® 310B/320 adhesive that is available from Lord Corporation of Cary, N.C. Adhesive 52 is generally characterized as having a high viscosity at room temperature and capable of curing at temperatures of 100° C. or lower. Adhesive 52 generally consists of essentially epoxy and amine having a ratio of 2.5 parts epoxy to one part amine curative. Adhesive 52 may be spread on bottom surface 46 and area 50 . Monitoring device 32 is then placed on area 50 with sufficient pressure to squeeze excess adhesive 52 out from under monitoring device 32 . The excess adhesive 52 is removed and monitoring device is held in place by a suitable device such as a clamp or a piece of tape (not shown). Monitoring device 32 is held in place and adhesive 52 is allowed to cure for 16 to 24 hours. When a faster cure is desired, heat can be applied to decrease the cure period. Adhesive 52 is substantially rigid when it cures.
Rigid cured adhesives are not generally compatible with areas of tire 10 that move and flex when tire 10 is used. The above adhesive attachment system functions best when innerliner 24 is thick enough to allow inner surface 26 thereof to form a rigid bond with adhesive 52 . Innerliners 24 on off-the-road tires 10 and on many truck and bus tires are typically thick enough to allow attachment 30 to properly function. The rigid bond is not disturbed or broken when tire 10 and innerliner 24 flex as a result of forces on tire 10 because of the thickness of innerliner 24 . As can be perhaps best seen in FIG. 5, a significant portion 54 of innerliner 24 remains intact between roughened portion 50 and the body of tired 10 . Innerliner portion 54 flexes with tire 10 and functions as a buffer that accommodates the flexing and movement of tire 10 without breaking the bond between adhesive 52 and innerliner 24 . This accommodation is possible because innerliner 24 is thick in off-the-road and on certain truck and bus tires 10 . When the thickness of portion 54 of innerliner 24 is decreased, the flex and movement of the body of tire 10 have a better chance of breaking the rigid adhesive 52 that connects monitoring device 32 to innerliner 24 . When attachment 30 of the present invention is used on innerliner 24 of an off-the-road or truck and bus tires, innerliner portion 54 flexes enough throughout the life of tire 10 to prevent the bond between adhesive 52 and innerliner 24 from breaking throughout the life of tire 10 .
Attachment 30 may also be used to connect monitoring device 32 to a different location on tire 10 such as the top surface 60 of tire 10 as depicted in the dashed lines shown in FIG. 1. A monitoring device 32 may be attached to top surface 60 when the configuration of tire 10 results in top portion 60 having low flex properties.
Attachment 30 thus achieves the objectives of the present invention by providing a lightweight attachment that securely attaches monitoring device 32 to innerliner 24 throughout the life of tire 10 . Tire 10 thus does not have to be excessively counterbalanced because attachment 30 is lightweight. Attachment 30 may also be easily created by automated equipment on an existing automated tire manufacturing line because attachment 30 does not require additional structural elements to be added to tire 10 or monitoring device 32 such as the flaps of the prior art that cover monitoring device 32 to hold monitoring device 32 in a pocket. Likewise, attachment 30 further does not require monitoring device 32 to be embedded within the body of tire 10 .
Accordingly, the improved attachment for connecting a monitoring device 32 to innerliner 24 of tire 10 is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but 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.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries, and principles of the invention, the manner in which the attachment of the present invention is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims.
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An attachment between a monitoring device and an innerliner of a tire includes the use of an epoxy adhesive that bonds the monitoring device directly to the inner surface of the innerliner of the tire. The innerliner is first roughened in a manner that provides a roughened portion of the innerliner without removing the entire thickness of the innerliner. The entire thickness of the innerliner is not removed because the innerliner is preferably more than {fraction (1/16)} of an inch thick. The thickness of the innerliner allows the rigid cured epoxy to bond the monitoring device to the inner surface of the innerliner while allowing the innerliner to flex with the tire so as to not break the seal between the rigid epoxy and the innerliner. The monitoring device is preferably located at a low flex area of the tire to help avoid the problem of the innerliner flexing.
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This application is a Continuation-In-Part Application of PCT International Application No. PCT/JP03/016960 filed on Dec. 26, 2003, which designated the United States.
FIELD OF THE INVENTION
The present invention relates to a substrate supporting structure and a plasma processing device. The term “semiconductor processing” used herein implies various processes to manufacture a semiconductor device and/or a structure including wiring, electrodes, and the like connected to the semiconductor device on a substrate to be processed, by forming a semiconductor layer, an insulating layer, a conductor layer, and the like, after a predetermined pattern, on the substrate to be processed, e.g., a semiconductor wafer, an LCD (Liquid Crystal Display) or an FPD (Flat Panel Display).
BACKGROUND OF THE INVENTION
With the recent trend of highly integrated and high-performance semiconductor device, improvement in productivity of manufacturing the semiconductor is very essential to realize cost reduction. As for a method for improving the productivity, increasing a diameter of a semiconductor substrate may be enumerated. Conventionally, a 200 mm substrate has been used as a semiconductor substrate (wafer), but, now, a 300 mm substrate is mainly used. If a semiconductor device is fabricated by using a 300 mm substrate of a large diameter, the number of semiconductor devices, which can be produced by using one sheet of substrate, is increased, thereby improving the productivity.
In case of using a 300 mm substrate, the conventional semiconductor device for processing a 200 mm substrate should be replaced with a device capable of processing a 300 mm substrate. In this case, a substrate supporting structure for supporting the substrate becomes scaled up, so that the semiconductor processing device such as plasma processing device or the like has to be also large-scaled. Thus, the footprint of the semiconductor processing device is increased, and the number of devices, which can be disposed in a semiconductor production factory, is accordingly decreased to thereby lower the productivity of the semiconductor device. Further, if components for a 200 mm substrate are scaled up to be used for a 300 mm substrate while employing the conventional substrate supporting structure as it is, a substantial cost increase is incurred.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a substrate supporting structure and a plasma processing device for semiconductor processing capable of realizing a scaling-down for miniaturization and reducing cost.
It is another object of the present invention to provide a plasma processing device capable of increasing at least inter-surface uniformity of a film formed on a substrate to be processed.
In accordance with the one aspect of the present invention, there is provided a substrate supporting structure for semiconductor processing including: a mounting table for mounting thereon a substrate to be processed; and a support part, disposed to be downwardly extended below the mounting table, for supporting the mounting table, wherein the mounting table contains an electrode part; a first insulating layer for covering a periphery of the electrode part; a second insulating layer for covering a bottom surface of the electrode part; and a first conducting layer covering the first and second insulating layers, wherein the support part contains a conductive transmission path for supplying a power to the electrode part; a third insulating layer for covering a periphery of the transmission path; and a second conducting layer for covering a periphery of the third insulating layer, and wherein the electrode part of the mounting table, the first and the second insulating layers and the first conducting layer are coaxially configured; the conductive transmission path of the support part, the third insulating layer and the second conducting layer are coaxially configured; the electrode part and the conductive transmission path are integrally formed; and the first and the second conducting layers are electrically connected to each other, and wherein a first channel for supplying a heat exchange medium into the electrode part is formed; and a second channel communicated with the first channel is formed in the conductive transmission path.
In accordance with another aspect of the present invention, there is provided a plasma processing device, including: an airtight processing chamber for accommodating therein a substrate to be processed; a gas supply unit for supplying a processing gas into the processing chamber; a gas pumping unit for exhausting the processing chamber; a mounting table, disposed in the processing chamber, for mounting thereon the substrate; and a support part, disposed to be downwardly extended below the mounting table, for supporting the mounting table, wherein the mounting table contains an electrode part; a first insulating layer for covering a periphery of the electrode part; a second insulating layer for covering a bottom surface of the electrode part; and a first conducting layer covering the first and second insulating layers, wherein the support part contains a conductive transmission path for supplying a power to the electrode part; a third insulating layer for covering a periphery of the transmission path; and a second conducting layer for covering a periphery of the third insulating layer, and wherein the electrode part of the mounting table, the first and the second insulating layers and the first conducting layer are coaxially configured; the conductive transmission path of the support part, the third insulating layer and the second conducting layer are coaxially configured; the electrode part and the conductive transmission path are integrally formed; and the first and the second conducting layers are electrically connected to each other, and wherein a first channel for supplying a heat exchange medium into the electrode part is formed, and a second channel communicated with the first channel is formed in the conductive transmission path.
In accordance with still another aspect of the present invention, there is provided a plasma processing device, including: an airtight processing chamber for accommodating therein a substrate to be processed; a gas supply unit for supplying a processing gas into the processing chamber; a gas pumping unit for exhausting the processing chamber; a mounting table, disposed in the processing chamber, for mounting thereon the substrate; and a conductive extension member for surrounding the substrate mounted on the mounting table, the extension member having a surface in parallel with that of the substrate, wherein the mounting table contains an electrode part to which a power is applied; a pedestal insulation layer for covering a bottom surface and a side of the electrode part; and a pedestal conduction layer, electrically connected to the support conduction layer, for covering at least a part of the bottom surface and the side of the pedestal insulation layer; and the electrode part, the pedestal insulation layer and the pedestal conduction layer are coaxially configured, and wherein the extension member is disposed on the pedestal insulation layer while being electrically insulated from the electrode part and the pedestal conduction layer; in the side of the pedestal insulation layer, a top end of the pedestal conduction layer is disposed to be placed below a bottom portion of the electrode part; and impedance between the extension member and the pedestal conduction layer is set to be greater than impedance between the electrode part and the pedestal conduction layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 offers a configuration view showing a plasma processing device containing a substrate supporting structure for semiconductor processing in accordance with a first embodiment of the present invention;
FIG. 2 describes a cross sectional view showing a magnified substrate supporting structure shown in FIG. 1 ;
FIG. 3 sets forth a cross sectional view showing a part of the substrate supporting structure shown in FIG. 1 ;
FIG. 4 presents a cross sectional view showing a magnified X part shown in FIG. 3 ;
FIG. 5 provides a cross sectional view showing a magnified Z part shown in FIG. 4 ;
FIG. 6 describes a transversal cross sectional view taken along Y-Y line shown in FIG. 2 ;
FIGS. 7A and 7B present partial cross sectional views showing a substrate supporting structure in accordance with a modified example of the first embodiment;
FIG. 8 is a graph showing a measurement result of self-bias potential in case of applying a high frequency power to a mounting table;
FIG. 9 presents a table showing process conditions;
FIG. 10 describes a schematic configuration cross sectional view showing a schematic configuration of a plasma processing device;
FIG. 11 offers a schematic configuration view showing a configuration of a main part of the plasma processing device shown in FIG. 10 ;
FIG. 12 presents a magnified partial cross sectional view schematically showing a configuration of an outer periphery of the mounting table;
FIGS. 13A and 13B are circuit diagrams showing equivalent circuits for a plasma in the plasma processing device and a lower electrode; and
FIG. 14 shows a magnified partial cross sectional view of the plasma processing device in accordance with a modified example of the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following discussion, identical reference numerals will be assigned for corresponding parts having substantially same functions and configurations, and redundant explanations will be omitted unless necessary.
First Embodiment
FIG. 1 is a configuration view showing a plasma processing device including a substrate supporting structure for semiconductor processing in accordance with a first embodiment of the present invention. A plasma processing device 10 is configured to perform a sputter etching or a reactive etching on a silicon oxide film, a metal oxide film or the like, which is formed on a semiconductor wafer as a substrate to be processed.
As shown in FIG. 1 , the plasma processing device 10 includes a processing chamber 20 for receiving thereinto a substrate W to be processed. To the processing chamber 20 , a gas supply unit 30 for supplying a processing gas thereinto is coupled. An excitation mechanism 40 for converting the processing gas into a plasma is disposed at an outer upper side of the processing chamber 20 . A mounting table 51 of a substrate supporting structure 50 for supporting the substrate W to be processed is disposed at an inner lower side of the processing chamber 20 .
The processing chamber 20 is formed by combining a conductive cylindrical lower side vessel 201 with an insulating cylindrical upper vessel or bell jar 401 . In a center of a bottom portion of the lower side vessel 201 , there is formed an opening, to which a downwardly protruded cylindrical exhaust chamber 202 is airtightly coupled. The exhaust chamber 202 has a planar outline, which is sufficiently small, compared to the processing chamber 20 ; and it is concentrically placed with the processing chamber 20 .
At a bottom portion of the exhaust chamber 202 , a support part 52 of the substrate supporting structure 50 is attached. The support part 52 of the substrate supporting structure 50 is fixed to the bottom portion of the exhaust chamber 202 by using an attachment ring 221 , screw reception rings 220 and 222 , clamping screws 219 and the like. Detailed descriptions thereof will be explained later with reference to FIG. 2 . The support part 52 is vertically elevated at a center of the exhaust chamber 202 , to thereby be coupled to the mounting table 51 through the opening of the bottom portion of the lower side vessel 201 .
An opening 218 is formed in a sidewall of the exhaust chamber 202 , and a gas pumping unit 204 , e.g., a turbo molecular pump or the like, is connected thereto through a gas exhaust line 203 . In case when performing an etching, particularly, a sputter etching, a space needs to be kept under a low pressure. For example, the processing space needs to be maintained at a low pressure in the range of 0.0133˜1.33 Pa, and preferably, 0.0133˜0.133 Pa, by using the gas pumping unit 204 such as a turbo molecular pump or the like.
An airtight processing space 402 in the processing chamber 20 is vacuum-exhausted by the gas pumping unit 204 through an exhaust space 202 A of the exhaust chamber 202 , which surrounds the support part 52 . Since the processing space 402 is exhausted through the exhaust space 202 A concentrically disposed therebelow, the processing space 402 can be uniformly exhausted compared to the case where the processing space 402 is exhausted through the side of the processing chamber 20 . Namely, the processing gas can be uniformly exhausted with respect to the substrate W as a center. Thus, the pressure in the processing space 402 becomes uniform, thereby producing the plasma uniformly. Hence, uniformity in etching rate while performing an etching on the substrate to be processed is enhanced.
At the bottom portion of the exhaust chamber 202 , there is disposed a shielding member or a shield cover 205 made of metal, e.g., aluminum, alloy thereof, that is grounded. An RF introducing component 206 for introducing an RF power into the mounting table 51 of the substrate supporting structure 50 is disposed in the shield cover 205 . The RF introducing component 206 is connected to a high frequency (RF) power supply 210 for a bias-applied through a matching unit 209 .
The mounting table 51 of the substrate supporting structure 50 has an electrode part 501 of a circular plate shape; and at the same time, the support part 52 of a columnar shape has a conductive RF transmission path 502 . The electrode part 501 and the transmission path 502 are formed as a unit by using a conductive material such as Al, alloy of Al, or the like, which are electrically connected to each other. A lower portion of the transmission path 502 is electrically connected to the RF introducing component 206 . Thus, the RF power is supplied to the electrode part 501 of the mounting table 51 from the RF power supply 210 though the transmission path 502 , and therefore, a bias voltage is applied to the substrate W to be processed. The shield cover 205 shields the RF to prevent any leakage thereof to the outside.
In the electrode part 501 of the mounting table 51 , there is formed a heat exchange medium chamber 507 (herein, a temperature control space, formed as a flow path) for accommodating therein a heat exchange medium, e.g., an insulating coolant fluid, for controlling temperature of the mounting table 51 . Meanwhile, in the transmission path 502 of the support part 52 , an introduction channel 215 and a discharge channel 216 are formed to supply the heat exchange medium into the temperature control space 507 and discharge it therefrom.
At a lower portion of the support part 52 , an insulation component 207 made of an insulating material such as ceramic, e.g., Al 2 O 3 , resin or the like, is disposed. The introduction channel 215 and the discharge channel 216 pass through the insulation component 207 to be coupled to metallic connection tubes 213 and 214 , respectively, that are attached to the insulation component 207 . Thus, the connection tubes 213 and 214 are electrically insulated from the RF transmission path 502 by the insulate component 207 . Peripheries of the insulation component 207 and the lower portion of the transmission path 502 are covered by a thermal insulator 217 .
The connection tubes 213 and 214 are coupled to a circulation unit (CU), e.g., a chiller, which functions to control the temperature. The heat exchange medium is circulated from the circulation unit (CU) to the temperature control space 507 through the introduction channel 215 and the discharge channel 216 , so that the temperature of the mounting table 51 is maintained at a predetermined temperature.
In a side of the lower side vessel 201 , there is formed a transfer port for substrate W, in which a gate valve 208 is disposed. While the gate valve 208 is opened, the substrate W to be processed can be loaded into the processing chamber 20 and unloaded therefrom. At that time, lift pins (e.g., three) of an elevation mechanism 211 are operated to assist transportation of the substrate W from the mounting table 51 .
A gas supply unit 30 includes an Ar gas supply source 305 connected to the gas supply line 311 through an Ar gas line 301 , and an H 2 gas supply source 310 connected thereto through an H 2 gas line 306 . Valves 302 and 304 and a mass flow controller 303 are disposed in the Ar gas line 301 . If the valves 302 and 304 are opened, Ar gas is supplied to the gas supply line 311 , wherein the flow rate of the gas to be supplied is controlled by the mass flow controller 303 . In the same manner, valves 307 and 309 and a mass flow controller 308 are disposed in the H 2 gas line 306 . If the valves 307 and 309 are opened, H 2 gas is supplied to the gas supply line 311 , wherein the flow rate of the gas to be supplied is controlled by the mass flow controller 308 .
The gas supply line 311 , through which Ar gas and H 2 gas are supplied, is connected to a gas supply ring 212 , which is annularly disposed on the lower side vessel 201 along the edge thereof. A gas supply groove 212 B is annularly formed in the gas supply ring 212 to discharge Ar gas or H 2 gas over the entire periphery of the gas supply ring 212 . Ar gas or H 2 gas is supplied towards the center of the processing space 402 through gas holes 212 A communicating with the gas supply groove 212 B. Ar gas or H 2 gas supplied to the processing space 402 turns into a plasma by an excitation mechanism 40 explained hereinafter.
An upper vessel, i.e., a bell jar 401 , is made of a dome shaped insulating material, e.g., quartz, ceramic (Al 2 O 3 , AlN) or the like. An antenna coil 404 of the excitation mechanism 40 is wound around the periphery of the bell jar 401 . The coil 404 is coupled to an RF power supply 403 through a matching unit 405 . The RF power supply 403 generates an RF power having a frequency in the range of, e.g., 450 kHz˜60 MHz (preferably, 450 kHz˜13.56 MHz).
If the RF power is supplied to the coil 404 from the RF power supply 403 , an induced magnetic field is formed in the processing space 402 . By the induced magnetic field, gas such as Ar, H 2 or the like, supplied into the processing space 402 , turns into a plasma. Such plasma is referred to as an inductively coupled plasma (ICP). With the plasma excited as above, a plasma processing, e.g., an etching, is performed on the substrate disposed on the mounting table 51 .
In the plasma processing device 10 , a diameter Da of the columnar support part 52 of the substrate supporting structure 50 can be made small. Thus, a diameter Db of the exhaust chamber 202 can be made small and the total plasma processing device 10 becomes small, to thereby reduce foot print (occupation area). Further, members such as the gas pumping unit 204 , e.g., turbo molecular pump, a pressure control valve (not shown) and the like are coupled through the gas exhaust line 203 to a gas exhaust port 218 formed on the sidewall of the exhaust chamber 202 (by using the space efficiently). Therefore, the gas exhaust line 203 or the gas pumping unit 204 can be disposed within the outline of the lower side vessel 201 or the excitation mechanism 40 (inside the range shown as the diameter Dc in FIG. 1 ).
FIG. 2 is a cross sectional view showing a magnified substrate supporting structure 50 shown in FIG. 1 . Hereinafter, the substrate supporting structure 50 will be discussed with reference to FIG. 2 . As described above, the substrate supporting structure 50 includes the circular plate shaped mounting table 51 and the columnar support part 52 concentrically disposed therebelow.
The mounting table 51 contains the aforementioned electrode part 501 to which the RF power is applied. The side of the electrode part 501 is covered with a ring block 508 made of a dielectric material such as quartz or the like. A bottom surface of the electrode part 501 is covered with a plate block 509 made of a dielectric material, e.g., quartz, and having in the center thereof holes, through which the transmission path 502 passes. A pedestal insulation layer is formed of the ring block 508 and the plate block 509 . The bottom surfaces and sides of the insulation layers 508 and 509 are also coated with a pedestal cover (pedestal conduction layer) 514 made of a conductive material such as Al, Ti or the like. The electrode part 501 , the insulation layers 508 and 509 and the conduction layer 514 are coaxially configured.
Meanwhile, the support part 52 includes the aforementioned conductive transmission path 502 for introducing the RF power. The transmission path 502 is coated with an insulator (support insulation layer) 513 made of a dielectric material such as PTFE (polytetrafluoroethylene) or the like. The insulator 513 is also coated with a support cover (support conduction layer) 515 made of a conductive material such as Al, Ti or the like, which is grounded. The transmission path 502 , the support insulation layer 513 and the support conduction layer 514 are coaxially configured.
The electrode part 501 and the transmission path 502 are molded as a unit by using a conductive material such as Al, alloy thereof or the like, so that these are electrically connected to each other. The ring block and the plate block (pedestal insulation layers) 508 and 509 and the insulator (support insulation layer) 513 are formed individually. The pedestal cover (pedestal conduction layer) 514 and the support cover (support conduction layer) 515 are molded individually. However, they are unified by welding, and at the same time, electrically connected to each other.
As described above, the temperature control space 507 accommodating therein the heat exchange medium (fluid) for uniformly maintaining the substrate to be processed at a predetermined temperature is formed in the electrode part 501 . In the temperature control space 507 , the introduction channel 505 and the discharge channel 506 , which are formed in the transmission path 502 , are connected to each other; and a flow path, through which the heat exchange medium flows between the introduction channel 505 and the discharge channel 506 , is formed.
FIG. 3 is a cross sectional view showing a part of the substrate supporting structure shown in FIG. 1 , which describes a cross section substantially normal to the cross section shown in FIG. 2 . A dielectric layer 503 made of a dielectric material, e.g., alumina (Al 2 O 3 ) or the like, is disposed on a top surface (and a side) of the electrode part 501 , with which the substrate W makes a contact. An electrode 504 is inserted into the dielectric layer 503 , disposed on the top surface, to form an electrostatic chuck together with the dielectric layer 503 . The electrode 504 is connected to a DC power supply (not shown) disposed at the outside of the processing chamber 20 through a wiring 516 , which extends through the transmission path 502 while being insulated. If a voltage is applied to the electrode 504 , an electrostatic polarization is generated at the dielectric layer 502 below the substrate W such that the substrate W is electrostatically adsorbed.
The dielectric layer 503 is formed by, e.g., ceramic spraying or the like. Alternatively, the dielectric layer 503 may be formed by using a method wherein a ceramic of sintered body is formed in a thin film to be jointed. Further, the dielectric layer 503 may be formed as a dielectric film such as aluminum nitride (AlN), SiC, BN or the like, without using alumina.
As described above, the substrate supporting structure 50 is coaxially configured so that mushroom shaped (T-shaped) conductive cores 501 and 502 connected to the RF power supply 210 for a bias are coated with the insulation layers (dielectric layers) 508 , 509 and 513 , and also, coated with conduction layers 514 and 515 that are grounded. By such a configuration, loss of the RF power is reduced; efficiency is improved; and the bias can be stably applied to the substrate to be processed.
In the first embodiment, PTFE is used as the support insulation layer (insulator) 513 . The reason is that PTFE has a low permittivity of about 2 and the loss of the RF power is reduced. That is, it is preferable that a low dielectric constant material is used for the support insulation layer 513 , taking the efficiency of RF power into consideration. In the same manner, it is preferable that pedestal insulation layers (ring block and plate block) 508 and 509 are formed by using a low dielectric constant material to reduce the loss in the RF power. However, followings should be noted.
In a region where the insulation layers (dielectric layers) 508 , 509 and 513 of the substrate supporting structure 50 are disposed, sealing members 511 and 512 are disposed in the plated block 509 to airtightly separate the mounting table 51 side from the support part 52 side. Namely, the pedestal insulation layers 508 and 509 are placed in a space communicating with the processing space 402 where the plasma is generated in the depressurized state. For the same reason, it is not preferable to use as a material for the pedestal insulation layers 508 and 509 a medium which releases lots of gas. Further, the insulation layers 508 and 509 are greatly influenced by any temperature variation such as a rise or a fall in the temperature due to the generation of plasma.
PTFE is porous microscopically compared to a dense material such as quartz or the like, and releases lots of gas in the depressurized state. Thus, it is not preferable to use PTFE in a vacuum vessel. Further, it is problematic that PTFE deforms or has no plasma resistance, to thereby tend to be etched.
Accordingly, as for the pedestal insulation layers 508 and 509 , it is preferable to employ such a material that hardly releases any gas in a depressurized vessel and is resistant to a temperature hysteresis, and more preferably, to employ a low dielectric constant material as possible. As for a material satisfying these requirements mentioned above, quartz may be enumerated, and alternatively, e.g., a resin material or the like may be used. Namely, it is preferable to use quartz for the insulation layers 508 and 509 , and PTFE for the support insulation layer 513 .
A focus ring 510 made of quartz or the like is disposed on the ring block 508 and the top surface (on which the substrate W is mounted) of the peripheral portion of the electrode part 501 . The focus ring 510 focuses the plasma on a wafer side in the processing chamber, to thereby make the plasma uniform. Further, the focus ring 510 prevents the ring block 508 and the insulating layer 503 from being damaged due to the plasma.
As mentioned above, the introduction channel 505 and the discharge channel 506 for supplying the heat exchange medium to the electrode 501 and discharging it therefrom, respectively, are formed in the transmission path 502 . Hence, as described below, the configuration of the substrate supporting structure 50 is simplified, so that the number of components is reduced, and at the same time, scale-down can be realized.
In the conventional substrate supporting structure, the RF introduction path for applying a bias to the mounting table, and the channel for introducing the heat exchange medium into the mounting table or discharging it therefrom are formed individually. Therefore, there is required a space below the mounting table, where respective components are to be disposed. Further, components of the RF introduction path and the heat exchange medium path are needed, respectively, and the number of components is large to thereby make the configuration complicated. Still further, since the size of the entire mounting table should be large, a volume to be cooled is increased, and thus, resulting in deterioration of the cooling efficiency.
In the substrate supporting structure 50 in accordance with the first embodiment, the introduction channel 505 and the discharging channel 506 are formed in the transmission path 502 , so that the space for disposing the RF introduction path can be commonly shared for the heat exchange medium path. Accordingly, it is possible to reduce the number of components thereof to thereby simplify the configuration and make the space small, which in turn makes it possible to realize the scaling-down of the substrate supporting structure. For example, as shown in FIG. 2 , it is possible to make the diameter Da of the support part 52 small, wherein the support part 52 contains the transmission path 502 , the introduction channel 505 and the discharging channel 506 . As a result, it is possible to make the diameter Db of the exhaust chamber 202 small, wherein the exhaust chamber 202 contains the support cover 515 , and thus, realizing the scaling-down of the substrate supporting structure 50 .
As for the heat exchange medium, an insulating fluid, e.g., fluorine based fluid (galden) or the like, may be used, since an RF current is applied to the electrode part 501 . Thus, the substrate to be processed is cooled through the mounting table 51 while securing insulation, so that the temperature of the substrate W to be processed can be maintained constant.
The substrate supporting structure 50 is fixed to the exhaust chamber 202 by using an attachment ring 221 , ring shaped screw reception rings 220 and 222 , and clamping screws 219 . The attachment ring 221 is of a substantially circular plate shape having in the center thereof a hole, through which the transmission path 502 passes. The attachment ring 221 is fixed to the transmission path 502 by a screw (not shown). The insulating screw reception ring 220 and metallic screw reception ring 222 are disposed between the attachment ring 221 and the support cover 515 such that they apply upward pressure to the support cover 515 by using the clamping screws 219 , which are screwed into screw holes formed in the attachment ring 221 . By clamping power of the clamping screws 219 , the transmission path 502 of the substrate supporting structure 50 is extended downward, i.e., towards the shield cover 205 . Therefore, the transmission path 502 and the electrode part 501 , as a unit, are pressurized to be adhered closely to the plate block 509 , and the plate block 509 is pressurized to be adhered closely to the cover 514 . As a result, the processing space 402 can be kept airtightly by the sealing ring 511 inserted between the electrode part 501 and the plate block 509 and the sealing ring 512 inserted between the plate block 509 and the pedestal cover 514 .
As mentioned above, it is possible to apply weight load needed for airtight sealing to the sealing rings 511 and 512 without using a metal screw. Hence, the processing space 402 can be assured to be airtightly kept in a state where there is no metal contamination source present in the processing space 402 where the plasma is excited.
Back to FIG. 3 again, it describes a cross section substantially normal to the cross section shown in FIG. 2 . As illustrated in FIG. 3 , in the transmission path 502 , there is formed a gas flow passage 517 for introducing a gas, that transfers heat at a high rate between the surface of the dielectric layer 503 and the substrate W to be processed. During the plasma processing, the heat transfer gas is supplied to improve the thermal conductivity between the mounting table 51 and the substrate W to be processed, thereby efficiently cooling the substrate W to be processed. Further, as described above, the wiring 516 is disposed in the transmission path 502 to be extended therein while being insulated and is connected to a DC power supply (not shown) disposed outside the processing chamber 20 . The substrate W is electrostatically adsorbed by applying a voltage to the electrode 504 of the electrostatic chuck disposed on the mounting table 51 through the wiring 516 .
FIG. 4 is a cross sectional view showing a magnified X part shown in FIG. 3 . As shown in FIG. 4 , the gas flow passage 517 communicates with a plurality of grooves 517 A formed on the surface of the mounting table 51 . The heat transfer gas, e.g., Ar, He or the like, is introduced into the grooves 517 A through the gas flow passage 517 . The electrode 504 of the electrostatic chuck is made of metal, e.g., W or the like. The electrode 504 is embedded between the upper and lower dielectric layers 503 and 518 made of, e.g., a thermally sprayed film of Al 2 O 3 or the like.
FIG. 5 is a cross sectional view showing a magnified Z part shown in FIG. 4 . As illustrated in FIG. 5 , the wiring 516 is made of a metal, e.g., Ti or the like. The wiring 516 is introduced into an insertion hole 501 a of a diameter La which is formed on the electrode part 501 . A ring 501 b made of Al is disposed in the insertion hole 501 a by, e.g., beam welding, and the wiring 516 is attached to a hole formed in the ring 501 b.
The wiring 516 has a bar-shaped wiring portion 516 a . On the bar-shaped wiring portion 516 a , there is formed a block-shaped step portion 516 b having a diameter larger than that of the wiring portion 516 a . On the step portion 516 b , there is formed a block-shaped step portion 516 c having a diameter smaller than that of the step portion 516 b . Further, on the step portion 516 c , there is formed a block-shaped step portion 516 d having a diameter smaller than that of the step portion 516 c . At sidewalls of the step portions 516 b , 516 c and 516 d , and parts of the step portions 516 b and 516 c which face the electrode 504 , an insulating film 516 i of thickness of 500 μm is formed by, e.g., Al 2 O 3 thermal spraying. In case of applying a DC voltage to the electrode 504 , the DC voltage introduced to the wiring 516 is applied through the step portion 516 d that is making a contact with the electrode 504 .
The space of the insertion hole 501 a between the wiring 516 and the electrode part 501 is filled with insulating layers 516 f and 516 e made of, e.g., an insulating resin, so that the wiring 516 is isolated from the electrode part 501 . The insulating layers 516 f and 516 e and the wiring 516 are fixed to the electrode part 501 by using, e.g., an epoxy-based adhesive.
FIG. 6 is a transversal cross sectional view taken along Y-Y line indicated in FIG. 2 . As illustrated in FIG. 6 , the introduction channel 505 and the discharging channel 506 are formed in the transmission path 502 . The introduction channel 505 and the discharging channel 506 are surrounded by thermal insulators 505 A and 506 A, e.g., a thermally insulating tube, to increase thermal insulating effect between the heat exchange medium and the transmission path 502 . Preferably, the thermal insulators 505 A and 506 A may be made of a material having low thermal conductivity, e.g., a fluorine based resin such as Teflon, Vespel or the like. The reason is as follows.
If the plasma processing is performed on the substrate to be processed in the processing chamber, heat is generated from the plasma. Hence, the heat exchange medium of low temperature, which is supplied into the temperature control space 507 through the introduction channel 505 , is heated to a high temperature and will be discharged through the discharge channel 506 . At this time, if heat is exchanged between the introduction channel 505 and the discharge channel 506 in the transmission path 502 , cooling efficiency of the electrode part 501 will be deteriorated. If the introduction channel 505 and the discharge channel 506 are surrounded by the thermal insulators 505 A and 506 A, the heat from the discharge channel 506 is prevented from being transferred to the introduction channel 505 , thereby efficiently cooling the substrate W to be processed.
As described above, the introduction channel 505 , the discharge channel 506 , the gas flow passage 517 and the DC voltage introduction wiring 506 are all disposed within the transmission path 502 . Therefore, the substrate supporting structure becomes small and the number of components is reduced, thereby simplifying the structure and realizing the production cost reduction.
The outline of a method for processing the substrate W is as follows. First, the substrate W is supported by the substrate supporting structure 50 . Subsequently, a processing gas is supplied into the processing space formed in the processing chamber 20 from the gas supply unit 30 . Further, the processing gas turns into a plasma by the excitation mechanism 40 to perform a plasma processing on the substrate W.
Specifically, first, the gate valve for transfer 208 , which is formed in the processing chamber 20 , is opened to load the substrate W to be processed which will mounted on the electrode part 501 . Thereafter, the gate valve 208 is closed and the processing space 402 is exhausted through the gas exhaust port 218 to be depressurized to be kept at a predetermined pressure.
Subsequently, the valves 304 and 302 are opened, and Ar gas is supplied form the Ar gas supply source 305 into the processing space 402 while the flow rate thereof is controlled by the mass flow controller 303 . In the same manner, the valves 309 and 307 are opened, and H 2 gas is supplied form the H 2 gas supply source 310 into the processing space 402 while the flow rate thereof is controlled by the mass flow controller 308 . Thereafter, an RF power from the RF power supply 403 through the matching unit 405 , e.g., RF matching network, is supplied to the coil 404 to excite an inductively coupled plasma in the bell jar 401 .
For example, in the manufacturing process of the semiconductor device, the plasma processing device 10 may be used in a processing for removing an impurity layer containing an oxide film formed on a metal film formed on the substrate to be processed, or an oxide film such as a native oxide film formed on a silicon. By removing such an impurity layer, adhesivity between a film to be formed thereafter and an underlayer may be improved, or sheet resistance of a film to be formed may be lowered.
Specific conditions under which the impurity layer is removed are given as follows. For example, the pressure is in the range of 0.1˜13.3 Pa, and preferably, 0.1˜2.7 Pa. The temperature of the wafer is 100˜500° C. As for the flow rate of gas, that for Ar gas is 0.001˜0.03 L/mim; and that for H 2 gas is 0˜0.06 L/min, and preferably, 0˜0.03 L/min. The frequency of the RF power supply 403 is in the range of 450 kHz˜60 MHz, and preferably, 450 kHz˜13.56 MHz. The power of the bias RF power supply is within the range of 0˜500 W, and bias potential is in the range of −20˜−200 V. By performing the plasma processing for about 30 seconds under such conditions, e.g., a silicon oxide film (SiO 2 ) is removed by about 10 nm.
Further, in case of removing a metal oxide film, e.g., Cu 2 O, specific conditions therefore are as follows. The pressure is within the range of 3.99×10 −2 ˜1.33×10 −1 Pa. The temperature of the wafer is in the range of 0˜200° C. As for the flow rate of gas, that for Ar gas is in the range of 0.001˜0.02 L/min, and preferably, 0.001˜0.03 L/min; and that for H 2 gas is in the range of 0˜0.03 L/min, and preferably, 0˜0.02 L/min. The frequency of the RF power supply 403 is in the range of 450 kHz˜60 MHz, and preferably, 45 kHz˜13.56 MHz. The power of the bias RF power supply is in the range of 50˜300 W, and the bias potential is in the range of −150˜−25 V. By performing the plasma processing for about 30 seconds under such conditions, e.g., a Cu 2 O film is removed by about 20˜60 nm.
Still further, FIG. 9 shows the ranges of the frequencies of the plasma excitation RF and the bias RF and respective powers thereof, in the aforementioned process. Still further, in case of the bias RF, the range of the bias potential is also shown.
The substrate supporting structure 50 is not limited to those shown in FIGS. 2˜6 , and it may be variously modified and changed. FIGS. 7A and 7B are partial cross sectional views of the substrate supporting structure in accordance with a modified example of the first embodiment.
In a substrate supporting structure 62 shown in FIG. 7A , the dielectric layer 503 is formed only in a region that is not covered with the focus ring 510 on the top surface (to which the substrate W is contacted) of the electrode part 501 . As mentioned above, the part, in which the dielectric layer is formed, becomes simplified, so that the number of processings of, e.g., ceramic spraying, is reduced, and thus, lowering the production cost. Namely, the dielectric layer can be easily formed by such a method that ceramic powders are supplied into the plasma of an atmospheric pressure or vacuum to perform a plasma spraying coating on an object. Further, as described above, it is possible to variously change an area or a shape of the electrode part 501 to be coated with the dielectric layer, if necessary.
In a substrate supporting structure 64 shown in FIG. 7B , a focus ring 510 A is thinner than the focus ring 510 of the substrate supporting structure 50 . The height of the top surface (to which plasma is exposed) of the focus ring 510 A coincides with that of the dielectric layer 503 . In this case, specifically, non-uniformity in the bias potential in the vicinity of edge of the substrate W is improved. As a result, an improvement in the uniformity in a sputter etching rate of in-surface of the substrate W can be realized.
Further, a material of the focus ring may be changed to change permittivity thereof. In this case, since the bias potential in the vicinity of the wafer edge is changed, the in-surface uniformity in a sputter etching rate may be improved.
FIG. 8 is a graph showing measurement results of the self-bias potential, in case where a high frequency power is applied to the mounting table. Herein, in the plasma processing device 10 having the substrate supporting structure 50 mounted thereon in accordance with the first embodiment, an RF power was applied to the substrate supporting structure 50 , and a self-bias voltage Vdc was measured at the substrate supporting table. Further, for comparison, the voltage Vdc for the conventional substrate supporting structure was measured. In the conventional substrate supporting structure, the RF transmission path was thin compared to the substrate supporting structure 50 , and a coaxial structure as described above was not formed.
As for conditions of Vdc measurement, the flow rate of Ar gas was 2.9 sccm. The pressure in the processing chamber was 0.5 mTorr. The temperature of the mounting table was room temperature (about 20˜30° C.) in case of using the substrate supporting structure 50 ; and it was 200° C. in the conventional case. The plasma density was set at 2.5×10 10 atoms/cm 3 . For this, the RF power for plasma excitation was 1000 W in case of using the substrate supporting structure 50 ; and it was 800 W in the conventional case.
As illustrated in FIG. 8 , Vdc of the substrate supporting structure 50 in accordance with the first embodiment was higher, compared to the conventional case. For example, if the RF power applied to the mounting table was 300 W, Vdc was 126 V in the conventional case, and 162 V in case of using the substrate supporting structure 50 , corresponding to a potential of about 1.3 times.
The reason may be conjectured that, in the substrate supporting structure 50 in accordance with the first embodiment, the RF power is efficiently transferred by the coaxial structure using the transmission path 502 as a central conductor. Another reason may be considered that the introduction channel, the discharge channel, the DC wiring, the heat transfer gas path and the like are all disposed within the RF transmission path 502 , to thereby, lower impedance of the RF. That is, in the latter case, while the entire substrate supporting structure becomes small, the surface area of the transmission path 502 increases, and thus, lowering impedance of the RF.
Second Embodiment
In the aforementioned plasma processing device 10 , if the metal oxide formed on the surface of metal, e.g., copper, aluminum or the like, is etched, metal removed from the substrate W to be processed is scattered. Scattered metal is deposited onto the top surface of the insulating focus ring 510 around the substrate W to be processed, and thus, forming a metal film. If the metal film is grown, a discharge path may be formed between the substrate to be processed (semiconductor wafer) W and the conductive cover (pedestal conduction layer) 514 , which is grounded, through the metal film. In this case, since charged particles on the metal film flow on the cover 514 as a current, there may be incurred a loss of the RF power supplied to the electrode part 501 . For the same reason, the processing efficiency is lowered and the processing uniformity is deteriorated due to a decrease in the self-bias or abnormal discharge in the discharge path.
Further, an electromagnetic configuration on the surface of the mounting table 51 may be seriously changed due to the formation of a metal film. In this case, the change due to the aging of the plasma state on the mounting table 51 may occur, and reproducibility of processing will be deteriorated. Further, if a conductive metal film is formed in the focus ring 510 , the situation becomes practically same as the case where a lower electrode has an area larger than the substrate W to be processed. In this case, the self-bias is lowered; the etching rate is lowered; and hence, the processing uniformity (inter-surface uniformity) between plural substrates to be processed is deteriorated.
A second embodiment relates to a plasma processing device for resolving the aforementioned problems. Thus, a device in accordance with the second embodiment has an effective configuration for a case when processing a substrate having a conductive film. As for such a processing, there may be enumerated a processing for removing an oxide film formed on a surface of, e.g., Cu, Si, Ti, TiN, TiSi, W, Ta, TaN, WSi, poly-Si or the like.
FIG. 10 is a configuration diagram showing a plasma processing device including a substrate supporting structure for semiconductor processing in accordance with the second embodiment of the present invention.
As shown in FIG. 10 , a plasma processing device 70 has a cylindrical processing chamber 710 in which a mounting table 720 is disposed. The processing chamber 710 is connected to a gas supply unit 740 for supplying a processing gas thereinto. To a gas exhaust port 711 c formed in the center of bottom portion of the processing chamber 710 , there is airtightly connected a substantially cylindrical exhaust chamber 711 B, which is downwardly protruded. In the same manner as in the first embodiment, a support 730 for supporting the mounting table 720 is concentrically disposed in the exhaust chamber 711 B.
An exhaust unit (not shown) having a vacuum pump and the like is coupled to a sidewall of the exhaust chamber 711 B through a gas exhaust line 716 . By the exhaust unit, an inside of the processing chamber 710 is exhausted, and at the same time, it is set to be kept at a predetermined vacuum pressure, e.g., in the range of 0.1 mTorr˜1.0 Torr.
The processing chamber 710 is formed by combining a conductive cylindrical lower vessel 711 with an insulating cylindrical upper vessel or a bell jar 712 . The lower vessel 711 is made of a metal (conductor), e.g., aluminum, alloy thereof or the like. The bell jar 712 is made of an insulator, e.g., glass, ceramic (Al 2 O 3 , AlN) or the like.
Around the bell jar 712 , an induction coil 713 is wound. The induction coil 713 is connected to an RF power supply 751 through a matching unit 752 . From the RF power supply 751 , an RF power of, e.g., 450 kHz is supplied to the coil 713 , so that an induced electromagnetic field is formed in the bell jar 712 . Further, the lower vessel 711 and the coil 713 are grounded.
Between the lower vessel 711 and the bell jar 712 , a gas supply ring 714 is airtightly formed with a sealing material such as O-ring or the like. The gas supply ring 714 is connected to a gas source 741 (e.g., Ar gas) and a gas source 742 (e.g., H 2 gas) of the gas supply unit 740 , through valves and flow meters. The gas supply ring 714 has plural gas inlet openings disposed equi-spacedly around the processing chamber 710 . The gas inlet openings uniformly discharge a processing gas (plasma generation gas) supplied from the gas supply unit 740 towards the center of the bell jar 712 .
At a sidewall of the lower vessel 711 , there is formed an opening 711 a , in which a gate valve 715 is disposed. While the gate valve 715 is opened, the substrate W to be processed can be loaded into the processing chamber 710 and unloaded therefrom.
On a top portion of the bell jar 712 , an upper electrode 717 , which is grounded, is disposed to face in the direction toward the mounting table 720 . The upper electrode 717 is made of a conductive material such as aluminum, which is alumite processed. The upper electrode 717 serves as an electrode facing toward a lower electrode disposed on the mounting table 720 , and functions to prevent any failure of plasma ignition and to facilitate easy ignition. The upper electrode 717 fixes and assists the bell jar 712 through buffer members (plural pads, which are equi-spacedly disposed) 717 a made of, e.g. a resin and the like.
An electrode part (lower electrode) 721 is disposed on the mounting table 720 . The lower electrode 721 is coupled to an RF power supply 753 through an RF transmission path 731 in the support 730 , a matching unit 754 and the like. From the RF power supply 753 , an RF power of, e.g., 13.56 MHz is supplied to the lower electrode 721 , and a bias potential is applied to the substrate W to be processed. Further, the lower electrode 721 and the transmission path 731 are molded as a unit in the same manner as in the first embodiment.
In the lower electrode 721 , there is formed a heat exchange medium channel (temperature control space) 721 a as a flow path for flowing a heat exchange medium, e.g., an insulating cooling fluid, for adjusting the temperature of the mounting table 720 . Meanwhile, in the transmission path 731 of the support 730 , there are formed introduction channel 735 and discharge channel 736 for supplying the heat exchange medium in the temperature control space 721 a and discharging it therefrom.
The introduction channel 735 and the discharge channel 736 are coupled to a circulation unit CU, e.g., a chiller or the like, which functions to control temperature. The heat exchange medium is circulated from the circulation unit CU to the temperature control space 721 a of the mounting table 720 through the introduction channel 735 and the discharge channel 736 , so that the temperature of the mounting table 720 is maintained at a predetermined temperature. For example, the substrate W to be processed is controlled to be kept at a predetermined temperature in the range of −20˜10° C. Instead of the temperature control space 721 a , any temperature control means may be provided in the mounting table 720 . For example, a resistance heater may be built in the mounting table 720 .
The lower electrode 721 is covered with a dielectric layer (insulating layer) 722 such as alumina or the like, to be insulated from surroundings. The dielectric layer 722 forms a mounting surface of the mounting table 720 for mounting thereon the substrate W to be processed. An electrode 723 is inserted in the dielectric layer 722 of the mounting surface to form an electrostatic chuck therewith. The electrode 723 is connected to a DC power supply 755 disposed outside the processing chamber 720 through a wiring 737 , which extends through the transmission path 731 while being insulated. By applying a voltage to the electrode 723 , the substrate W to be processed is electrostatically adsorbed on the mounting table 720 .
Side and bottom surfaces of the lower electrode 721 are covered with an insulating layer 725 made of an insulating material such as quartz and the like. A part of the lower and side surfaces of the insulating layer 725 is also covered with a cover 726 made of a conductive material such as Al and the like. The lower electrode 721 , the insulating layer 725 and the conductive cover 726 are coaxially configured.
Meanwhile, the transmission path 731 of the support 730 is coated with an insulating layer 732 . The insulating layer 732 is also made of a conductive material such as Al and the like; electrically connected to the conductive cover 726 ; and coated with a cover 733 that is grounded. The transmission path 731 , the insulating layer 732 and the conductive cover 733 are coaxially configured.
Namely, the substrate supporting structure in accordance with the second embodiment also is coaxially configured such that the mushroom shaped conductive cores 721 and 731 connected to the RF power supply for the bias 753 are covered with the insulating layers (dielectric layers) 725 and 732 , and also, covered with the conductive covers 726 and 733 that are grounded. Since the conductive covers 726 and 733 are grounded, charges flow to the ground even though an induced electromagnetic field is formed in the covers 726 and 733 . For the same reason, a plasma is not produced in an exhaust space below the mounting table 720 when the RF power is applied to the lower electrode 721 . By such a configuration, the loss of the RF power is reduced, and the bias can be applied efficiently and stably to the substrate to be processed.
At an upper outer periphery of the mounting table 720 , there is disposed a conductive ring-shaped extension member 727 surrounding the substrate W to be processed. The extension member 727 has an exposed top surface in parallel with that of the substrate W to be processed (preferably, heights thereof are equal to each other) when the substrate W to be processed is mounted on the mounting table 720 . The extension member 727 is insulated from the electrode 721 by the dielectric layer 722 . Further, the extension member 727 is insulated from the conductive cover 726 by the insulating layer 725 or by having a sufficiently wide gap. In the second embodiment, the extension member 727 is insulated from all neighboring members, to which a potential is supplied. In other words, the extension member 727 is in a floating state where no potential is supplied.
It is preferable that the conductive extension member 727 is configured to totally surround the periphery of the substrate W to be processed. The extension member 727 is formed of various conductive materials such as metal, e.g., titanium, aluminum, stainless steel or the like, or low resistance silicon. Preferably, the extension member 727 is formed of titanium or alloy thereof that hardly produces particles and the like due to the peeling of conductor. Alternatively, the surface of the extension member 727 may be coated with titanium or alloy thereof.
Outside the processing chamber 720 , a driving source 761 formed of an electric motor, a fluid pressure cylinder and the like is disposed. The driving source 761 raises and lowers a plurality of lift pins 763 through a driving member 762 . By elevation of the lift pins 763 , the substrate W to be processed is elevated from the mounting surface of the mounting table 720 . By this, the lift pins 763 assists the substrate W to be transported to the mounting table 720 .
FIG. 11 is a schematic configuration view showing a configuration of a main part of the plasma processing device shown in FIG. 10 . The plasma processing device 70 includes a conductive sealing box 719 coupled to the lower vessel 711 to cover the upper side thereof. The bell jar 712 and the induction coil 713 are accommodated in the sealing box 719 . The sealing box 719 is grounded, which functions to shut off any plasma emission (Ultra Violet or the like) or electromagnetic field. Further, the upper electrode 717 is supported by a member 718 in an upper part of the sealing box 719 .
In the aforementioned plasma processing device 70 , a processing gas (e.g., gaseous mixture of Ar gas and H 2 gas) from the gas supply unit 740 is introduced into the processing chamber 710 through the gas supply ring 714 . At this time, the processing chamber 710 is exhausted through the exhaust chamber 711 B and the gas exhaust line 716 ; and it is set to be maintained at a predetermined pressure (vacuum), e.g., in the range of 0.1 mTorr˜1.0 Torr. In such a state, an RF power, e.g., in the range of 100˜1000 W, is applied to the induction coil 713 . By this, the processing gas turns into a plasma in the bell jar 712 , and a plasma region (P) is formed above the substrate W to be processed (see FIG. 10 ).
If an RF power is supplied to the electrode 721 of the mounting table 720 , a self-bias voltage is generated. By such a self-bias voltage, ions in the plasma are accelerated to collide with the surface of the substrate W to be processed, and etching is carried out.
In the plasma processing device 70 , a metal or an metal oxide on the surface of the substrate W to be processed, e.g., an oxide film on the surface of Cu, Si, Ti, TiN, TiSi, W, Ta, TaN, WSi, poly-Si or the like, is etched. In this case, as mentioned above, the metal is scattered from the substrate W to surroundings, so that a metal film may be formed in the surroundings. However, in the second embodiment, the aforementioned metal film is formed mainly on the exposed surface of the extension member 727 .
FIG. 12 is a magnified partial cross sectional view showing that a metal film M is formed on the extension member 727 , in the plasma processing device shown in FIG. 10 . As illustrated in FIG. 12 , a gap 728 for sufficiently insulating the discharge path is formed between the extension member 727 and the conductive cover 726 . For the same reason, even though the metal film M is formed on the extension member 727 , an electromagnetic environment at the outer periphery of the mounting table 720 is hardly changed. Namely, even though the metal film M is formed on the extension member 727 , currents does not flow to the ground, and an electrode area is not changed. Moreover, there is no problem that the discharge path is formed at the outer periphery of the mounting table 720 , or abnormal discharge occurs.
Further, since the conductive extension member 727 is sufficiently insulated from periphery members by the insulating layer 725 , there will be no current flow generated by the RF power supplied to the electrode 721 through the extension member 727 . Therefore, waste of processing power of the device resulting from a drift of the self-bias becomes reduced.
Namely, in the second embodiment, the conductive extension member 727 is disposed from the beginning, expecting the formation of the metal film M, so that electromagnetic situation around the substrate W is hardly changed although the metal film M is formed. Accordingly, the uniformity (inter-surface uniformity) in a processing performed on plurality of substrates can be improved, since the plasma is uniformly produced on the substrate.
One of the electromagnetic considerations is related with the insulation between the extension member 727 and the conductive cover 726 . If the upper portion of the cover 726 of the mounting table is close to the extension member 727 , a leakage in the power applied to the electrode 721 is increased and the processing cannot be performed efficiently and stably. In the configuration shown in FIG. 12 , a sufficiently long distance S through the gap 728 between the cover 726 and the extension member 727 is secured.
Specifically, in the second embodiment, it can be configured that impedance Z 2 (a distance S between the extension member 727 and the cover 726 ) between the extension member 727 and the cover 726 is greater than impedance Z 1 (a thickness of the insulating layer 725 ) between the lower electrode 721 and the cover 726 . These impedance values are obtained by using as a reference frequency the RF applied to the lower electrode 721 . By such a configuration, it is possible to reduce (substantially suppress) the current due to the RF power applied to the electrode 721 that flows through the extension member 727 . In other words, an impedance change between the electrode 721 and the cover 726 due to the extension member 727 is hardly generated, and the discharge path is hardly formed.
Further, as for a method for securing a sufficiently high insulation resistance (impedance) between the conductive cover 726 and the extension member 727 , an insulator (dielectric material) is disposed in the gap 728 such that it can be used to obtain a desired resistance by making a change in permittivity or shape thereof by design. For example, a dielectric material is disposed in the gap 728 indicated by the dotted line in FIG. 12 , so that substantial permittivity of the insulating material, disposed between the cover 726 and the extension member 727 , is changed. That is, impedance therebetween can be changed by disposing the insulator in the gap 728 , so that Z 2 may be designed to be greater than Z 1 . By doing this, the discharge path is not formed while the processing may be performed stably.
Further, in the second embodiment, an exposed surface of the conductive extension member 727 is configured in parallel with the surface of the substrate W to be processed (preferably, heights thereof are equal to each other), so that the surface area of the electrode 721 of the mounting table 720 is substantially increased. Namely, same electromagnetic environment is provided in case where a surface area of the electrode 721 becomes π·(D 2 )2 due to the extension member 727 , compared to the case where the surface area of the electrode 721 is π·(D 1 )2. Herein, D 1 is a radius of the electrode 721 (a radius of simulated circle having the same area as an object); and D 2 is a radius corresponding to an outer peripheral shape of the extension member 727 .
FIGS. 13A and 13B show simplified equivalent circuits of the mounting table 720 , for the cases when the electrode area of the mounting table 720 is assumed to be A 1 and A 2 and respective self-bias voltages are assumed to be V 1 and V 2 . Herein, the electrode areas A 1 and A 2 are π·(D 1 )2 and π·(D 2 )2, respectively, wherein A 1 <A 2 . In this case, following relationship is formed between the electrode area and the self-bias voltage.
( V 2/ V 1)=( A 1/ A 2) 4 (Relational equation 1)
Namely, as described above, in case when A 1 <A 2 , and hence, V>V 2 , as the electrode area is increased, the self-bias voltage is rapidly decreased. Therefore, if the extension member 727 is not disposed, the processing will proceed and the metal film M will be deposited, so that an effective electrode area of the mounting table will get increased. Accordingly, the self-bias voltage is gradually decreased, and the processing state will be changed. Contrary to this, in the second embodiment, there exists the extension member 727 from the beginning of the substrate processing, as shown in FIG. 13B . Moreover, although the processing proceeds and the metal film M is adhered, the effective electrode area is hardly changed. Therefore, the self-bias voltage is hardly changed, and the processing can be performed stably. Further, the extension member 727 is configured to be attached to the mounting table 720 and detached therefrom freely, the extension member 727 can be readily replaced. In this case, maintenance of the device may be simply carried out.
FIG. 14 is a magnified partial cross sectional view of the plasma processing device in accordance with the modified example of the second embodiment. This modified example has a configuration such that, compared to the configuration shown in FIG. 12 , the power leakage of the lower electrode 721 is reduced, and at the same time, it is unlikely to make the conductive cover 726 and the extension member 727 have a short circuit due to the metal film of by-product.
Specifically, as illustrated in FIG. 14 , in the relationship between a thickness of the insulating layer 725 and a position of top end of the conductive cover 726 , it is configured to satisfy the relationship of L<T. Here, L means a level difference between the bottom portion of the insulating layer 725 in the side thereof and the top end of the cover 726 . Further, T means the thickness of the insulating layer 725 between the lower electrode 721 and the cover 726 . In other words, in the side of the insulating layer 725 , the top end of the conductive cover 726 is configured to be placed below the bottom portion of the lower electrode 721 .
By this, it is possible to control impedances of Z 1 and Z 2 , thereby, improving uniformity of plasma.
While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. For example, in the first and second embodiments, the plasma etching device has been explained, but the present invention may be applicable to a plasma film forming device, a plasma ashing device or the like, in the same manner. The substrate to be processed is not limited to a semiconductor wafer, and a glass substrate, an LCD substrate or the like may be employed.
In accordance with the present invention, it is possible to provide a substrate supporting structure and a plasma processing device for semiconductor processing capable of realizing a scaling-down to reduce the overall size and reducing cost.
Further, in accordance with the present invention, it is possible to provide a plasma processing device capable of increasing at least inter-surface uniformity in a film formed on the substrate to be processed.
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A substrate supportingstructure ( 50 ) for semiconductor processing, comprising a mounting table ( 51 ) for placing a processed substrate (W) disposed in a processing chamber ( 20 ), wherein temperature control spaces ( 507 ) for storing the fluid used as a heat exchange medium are formed in the mounting table ( 51 ), a conductive transmission path ( 502 ) is disposed to lead a high frequency power to the mounting table ( 51 ), and flow channels ( 505, 506 ) feeding or discharging the heat exchange medium fluid to or from the temperature control spaces ( 507 ) are formed in the transmission path ( 502 ).
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BACKGROUND OF THE INVENTION
This invention relates to AM stereophonic receivers, and particularly to AM stereophonic receivers for receiving signals modulated according to the well known independent sideband (ISB) modulation technique. However, the invention is also useful in receivers for other composite amplitude and angular moduated stereo signals wherein a demodulated AM signal is used in conjunction with the angular modulation of such a composite signal for stereo reproduction.
U.S. Pat. No. 4,018,994 to Kahn describes an AM stereophonic receiver which includes an envelope detector, for detecting the amplitude modulation component of a received ISB AM stereo IF signal, and circuitry for detecting the quadrature modulation resulting from the phase modulation in the IF signal. The particular quadrature demodulation circuitry used by Kahn modifies the quadrature modulation component of the IF signal prior to quadrature detection for purposes of distortion correction.
In AM receivers, and particularly those with continuous tuning, it is often useful to have a non-flat automatic gain control (AGC) characteristic so that the signal level at the output of the envelope detector continuously increases with increasing received signal strength, rather than level off at some point. This characteristic is illustrated in FIG. 1, which is a graph of the output signal level from an envelope detector as a function of received signal level. If an ideal AGC circuit is used, the output signal level increases with increasing received signal level up to a certain level, and thereafter is flat as illustrated by curve 6 in FIG. 1. If no AGC is present, the output signal level increases linearly as a function of the input signal level as shown by curve 8 in FIG. 1. With a non-flat AGC circuit, the output signal level increases linearly with increasing input signal level up to a certain level, and thereafter increases at a lesser rate with respect to the input signal level, as shown by curve 7 in FIG. 1. A non-flat AGC characteristic is helpful to the operator of such a receiver in that tuning the receiver is easier, because the frequency at which maximum signal strength is received (i.e., the center of the band) is more easily sensed. Non-flat AGC also minimizes interstation noise and requires a lower value of maximum gain in a receiver's IF circuitry.
If a non-flat AGC characteristic is used in connection with an AM stereo receiver of the type described in the prior Kahn patent, which is illustrated in FIG. 2, the changing level A of the envelope detector output, corresponding to the carrier level at the detector (which is a function of tuning and received signal strength), will result in an improper correction signal being supplied to the inverse modulator 22 and, therefore, improper distortion correction. In FIG. 2, and elsewhere hereinafter, X + represents the stereo sum signal (L+R) and X - represents the stereo difference signal (L-R).
It is, therefore, an object of the present invention to provide a receiver which is generally of the distortion correcting type disclosed in the aforementioned Kahn patent, but which has a non-flat AGC characteristic.
SUMMARY OF THE INVENTION
The present invention is applicable in a receiver for receiving a signal having a carrier which has been amplitude modulated with a first modulating signal and angle modulated with a second modulating signal. In particular, the invention is applicable in a receiver wherein there are provided first means for demodulating such as composite signal to obtain a first demodulated signal representative of the first modulating signal and wherein the first demodulated signal has a signal level dependent on received carrier level. The receiver also includes second means for demodulating the composite signal to obtain a second demodulated signal representative of the quadrature modulation component produced by angular modulation of the carrier by the second modulating signal, the second demodulating means being responsive also to the first demodulated signal. In accordance with the invention, there is provided an improvement wherein the second demodulating means includes means responsive to the first demodulated signal for deriving therefrom a modification signal which is substantially independent of carrier signal level. The second demodulating means also includes means responsive to the modification signal for modifying the quadrature modulation component of the received signal thereby to derive the second demodulated signal.
The first demodulating means may comprise an envelope detector, in which case the first demodulated signal has a magnitude multiplier term which is dependent on the received carrier level. The means for deriving the modification signal may therefore comprise means for normalizing the first demodulated signal. The normalizing means in one case may be the series combination of a logarithmic amplifier and a high pass filter. The output of the logarithmic amplifier and high pass filter can thereafter be provided to a subtractive type inverse modulator for modifying the quadrature component of the received signal by acting on either the composite signal or the quadrature demodulated signal. In another case, the normalizing means may comprise the series combination of a low pass filter and a divider. In this case, the inverse modulator preferably comprises a reciprocal type inverse modulator. As noted previously, the invention is of particular advantage in receivers which have a non-flat AGC characteristic.
In accordance with another aspect of the invention, there is provided apparatus for receiving annd demodulating a composite AM stereo signal wherein a stereo sum signal is amplitude modulated on a carrier and a stereo difference signal is phase modulated on the carrier. The apparatus includes first means for amplitude demodulating the received composite signal to derive therefrom a first demodulated signal representative of the stereo sum signal and having a signal characteristic dependent on the carrier signal level of the composite signal. There is provided a second means which is responsive to the first demodulated signal, for deriving a modification signal having signal characteristics independent of the carrier signal level of the composite signal. Third means are provided which is responsive to the modification signal for modifying the quadrature modulation component of said composite signal.
In one embodiment, the second means comprises a logarithmic amplifier which is responsive to the first demodulated signal and has an output signal representative of the sum of a first logarithmic signal, which is proportional to the logarithm of the DC component of the first demodulated signal level, and a second logarithmic signal, which is representative of the stereo sum signal. A high pass filter is provided for removing the first logarithmic signal, whereby the modification signal comprises substantially only the second logarithmic signal. In this embodiment, the third means preferably comprises a subtractive type inverse modulator.
In another embodiment, the second means comprises a low pass filter for deriving the DC component of the first demodulated signal and a divider for dividing the first demodulated signal by the DC component, whereby the divider output comprises the desired modification signal. In this embodiment, the third means preferably comprises a reciprocal type inverse modulator.
In either of the above described embodiments the inverse modulator may be introduced either ahead of or following quadrature demodulation of the composite signal, so as to modify the quadrature modulation component of the signal.
For a better understanding of the present invention, together with other and further objects, reference is made to the following description, taken in conjunction with the accompanying drawings, and its scope will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating detected signal output level as a function of input signal level for various AGC characteristics.
FIG. 2 is a block diagram of a composite signal receiver in accordance with the prior art.
FIG. 3 is a block diagram of a composite signal demodulating apparatus usable in a receiver according to the present invention.
FIG. 4 is a block diagram of an laternative configuration of a composite signal demodulating apparatus usable in a receiver according to the present invention.
FIG. 5 is a block diagram illustrating an alternative arrangement for the embodiments shown in FIGS. 3 and 4.
DESCRIPTION OF THE INVENTION
Referring to FIG. 2, which illustrates in block diagram form a receiver according to the principles of Kahn U.S. Pat. No. 4,018,994, there is shown a receiver 10 for receiving and demodulating AM stereo signals, and particularly signals of the type known as independent sideband (ISB) AM stereo signals. This receiver is more fully described in the aforementioned Kahn patent, but will be reviewed for purposes of clarifying the nature and scope of the present invention.
Receiver 10 includes an antenna 12 and RF and IF circuits 14 which receive a composite amplitude and phase modulated AM stereo signal and provide a composite IF signal output on lead 15 which is supplied to a first demodulating means, comprising envelope detector 16, and a second demodulating means, comprising the combination of inverse modulator 22 and quadrature detector 26. The output of envelope detector 16 consists of a first demodulated signal (A+AX + ) or A(1+X + ) which is representative of a first modulating signal, the stereo sum signal (X + ), which is amplitude modulated onto the carrier at the transmitter. Assuming that IF circuit 14 includes an AGC circuit which provides a non-flat AGC characteristic, such as that described previously herein with respect to curve 7 in FIG. 1, as a result, the envelope detector output includes a magnitude modifier (A) which is dependent on the carrier signal level of the received composite signal. In accordance with the prior U.S. patent to Kahn, it is desirable to use the AC components of the demodulated signal, represented by X + , for modifying the quadrature modulation component of the IF signal in inverse modulator 22 prior to supplying the modified IF signal to quadrature detector 26. The DC component, represented by (1) in the expression (1+X + ), would normally be discarded by means of a series AC coupling capacitor 9.
However, if the IF circuit 14 has a non-flat AGC characteristic such as curve 7 shown in FIG. 1, the amplitude of the modification signal supplied on lead 20 to inverse modulator 22 will vary according to the carrier level at envelope detector 16, which is a function of receiver tuning and received signal strength. As a result, the modified IF signal at the output of inverse modulator 22 will include the undesired magnitude modifier (A) which is a function of the carrier signal level. Accordingly, the signal at the output of quadrature detector 26 has improper distortion correction because of the presence undesired carrier level dependent magnitude modifier (A) in the modification signal supplied to inverse modulator 22. More particularly, the inverse modulation percentage may be the correct value to cancel the cross modulation distortion in the X - signal at only one carrier level (A), since the percent inverse modulation is dependent upon the carrier level (A).
The outputs of envelope detector 16 and quadrature detector 26 are supplied to 90 degree phase difference networks and a combining matrix, designated by block 28 in FIG. 2. The matrix in 28 develops separate left and right stereo signals L and R as fully described in the aforementioned Kahn patent.
As previously indicated, it is an object of the present invention to provide a receiver of the general type shown in FIG. 2 which includes distortion correction to the quadrature modulation component of the received signal and wherein the distrotion correction is substantially independent of carrier signal level at envelope detector 16. Various embodiments of such receivers are described herein with reference to FIGS. 3, 4 and 5.
FIG. 3 illustrates demodulating apparatus 29 which provides distortion correction to the quadrature component of the received signal in a manner which is independent of received carrier signal level. Apparatus 29 may be used in conjunction with the same antenna 12 and RF and IF circuits 14 as are used in the receiver 10 of FIG. 2. The IF composite signal on lead 15 can reflect a non-flat AGC characteristic which, as previously mentioned, is desirable particularly for continuous-tuned AM receivers. The first demodulating means, envelope detector 16, provides an output on lead 18 to unit 28 which is a first demodulated signal (A+AX + ) or A(1+X + ), having a magnitude modifier (A) which is dependent on the received carrier signal level at the detector. This first demodulated signal is supplied to logarithmic amplifier 30 which provides an output signal on lead 32 that is the sum of a first logarithmic signal, log E (A) which is representative only of the carrier signal level dependent modifier (A), and a second logarithmic signal, Log E (1+X + ) which is representative only of the stereo sum modulating signal X + . This occurs because of the known mathematical relationship log (X)(Y)=Log (X)+Log (Y). Since the carrier signal level, and therefore the signal log E (A), changes relatively slowly, it may be removed by high-pass filter 34 having a low-frequency cut-off of 5 Hz, for example, to develop an output modification signal on lead 36 which is representative substantially only of the stereo sum signal modulation, and is substantially independent of the received carrier signal level. This modification signal is shown as being applied to a substractive type inverse modulator 22, which is also supplied with the IF signal via lead 15. Subtractive type inverse modulator 22 has a transfer characteristic of (1-0.5B), for example, (where B=log E (1+X + )) and modifies the IF signal to develop a modified IF signal which is supplied, via lead 38, to quadrature detector 26. The modification performed by substractive inverse modulator 22, using the logarithmic signal representative of the stereo sum modulating signal X + , provides appropriate distortion correction to the quadrature modulation component of the IF signal prior to quadrature detection. Quadrature detector 26 demodulates the quadrature component of the modified IF signal to provide an output on lead 40 which is proportional to the stereo difference signal X - and has proper distortion correction. The stereo sum and difference representative signals present on leads 18 and 40, respectively, are then phase shifted and combined in the 90 degree phase difference networks and matrix unit 28 illustrated in FIG. 3 to derive separate left and right stereo signals.
The combination of the subtractive type inverse modulation function (1-0.5B) and the log function B=log E (1+X + ) provides the equivalent of a reciprocal type inverse modulation function 1/(1+0.5X + ) When the log function has a magnitude which corresponds to the natural logarithm (i.e., log E ), the first three terms in the expansion of 1/(1+0.5X + ) and of the function 1-0.5 log E (1+X + ) are identical. Good correspondence (for example, within some close tolerance like±a few percent) results over a somewhat greater range of X + values when the log function has a magnitude of 0.95 log E .
FIG. 4 is a block diagram of another demodulating apparatus 41 which provides for removal of the carrier signal level dependent modifier (A) from the output of envelope detector 16, thereby to develop a suitable modification signal for use in inverse modulator 22. In the demodulating apparatus 41 of FIG. 4, the output (A+AX + ) of the first demodulator 16 is supplied to a low pass filter 42 having a high-frequency cut-off of 5 Hz, for example, whose output on lead 44 is a DC component representative of the term (A). The AC components (AX + ) of the first demodulated signal are supplied via DC blocking capacitor 9 and lead 46 to divider 48 which divides the (AX + ) term by the DC term (A) to derive a normalized signal X + which is representative of the sum stereo signal and is independent of carrier signal level. This signal is the modification signal which is supplied on lead 50 to inverse modulator 22. Inverse modulator 22 in this case is preferably a reciprocal type inverse modulator having a transfer characteristic of 1/(1+0.5X + ) for example, whereby proper distortion correction is provided to the quadrature modulation component of the IF signal supplied to inverse modulator 22 on lead 15. The resulting modified IF signal is supplied, via lead 52, to quadrature detector 26 to derive a second demodulated signal proportional to the stereo difference signal X - and having proper distortion correction. The first and second demodulated signals are then phase shifted and combined in the 90 degree phase difference networks and matrix unit 28 to derive separate left and right stereo signals.
It should be recognized that as an alternative the inverse modulation operation, which in the embodiments illustrated in FIGS. 3 and 4 is shown being performed on the IF signal prior to quadrature detection, can be performed equally as well on the output signal from the quadrature detector as shown in FIG. 5. In either case the desired distortion correction of the quadrature modulation component of the received signal is accomplished.
While there have been described what are believed to be the preferred embodiments of the present invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the true scope of the invention.
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In a receiver for composite amplitude and angle modulated signals and having a non-flat automatic gain control characteristic, there is provided apparatus for providing distortion correction to the quadrature component produced by the angular modulation in accordance with the amplitude modulation component. In accordance with the invention, the output of an amplitude demodulator is modified to remove the carrier signal level dependent magnitude multiplier and develop a modification signal which is used to inversely amplitude modulate the quadrature signal component to provide distortion correction over a range of carrier signal levels. Such inverse modulation can be provided before or after quadrature demodulation of the received signal.
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TECHNICAL FIELD
The invention relates to an anchorage for a laterally deflectable belt buckle.
BACKGROUND OF THE INVENTION
Usually, belt buckles are anchored to the vehicle seat or to the vehicle floor by flexible traction cables which, following insertion of the buckle tongue in the buckle head, permit alignment of the belt buckle to approximate the run of the belt webbing. The lower the forces opposing the lateral deflection of the belt buckle, the better the orientation of the belt buckle can be adapted to the run of the belt webbing. When, however, a slight bending moment opposes the lateral deflection of the belt buckle, the belt buckle may laterally deviate on insertion of the buckle tongue, thus making it necessary to design the flexural strength of the buckle anchorage greater than it would be desirable for an optimum run of the belt webbing.
BRIEF SUMMARY OF THE INVENTION
The invention provides an anchorage for a belt buckle arranged alongside a vehicle seat in a seat belt system, said anchorage allowing said belt buckle to be swivelled towards the vehicle occupant relatively easily but which is relatively difficult to be moved in the opposite direction. Accordingly, this anchorage permits, on the one hand, the belt buckle to adapt to the run of the seat belt whilst, on the other, making a shift of the basic position of the belt buckle difficult, if the buckle tongue is not latched in place. The anchorage according to the invention comprises the belt buckle which is affixed to the anchorage and which has a laterally deflectable buckle head. The anchorage has a flexible fitting to which the buckle head is secured and which opposes a deflection of the belt buckle towards the vehicle seat a lesser resistance than away from it.
In accordance with one aspect of the invention, an elastically deflectable supporting part is provided which at the side of the fitting, which in the fitted conditions is directed away from an associated vehicle seat, contacts the fitting and increases the bending resistance moment of the anchorage in the direction of the supporting part. The additionally provided supporting part increases in the fitted condition of the anchorage the bending resistance moment thereof in the direction laterally away from the associated vehicle seat, whereas by contrast the belt buckle is adjustable towards the vehicle seat without necessitating any greater force.
In accordance with the preferred embodiment, the supporting part is located pretensioned at the preferred elastically deflectable fitting in the non bent condition, i.e. in the basic position in the vehicle, thus preventing rattling in the anchorage when the vehicle is on the move.
In accordance with a further preferred embodiment, the fitting and the supporting part each and/or together form a leaf spring pack whereby the supporting part is coupled to the fitting merely at its vehicle floor end and contacts the fitting by its belt buckle end, the supporting part accordingly increasing the bending resistance only in one direction.
The belt buckle end of the supporting part is preferably rounded in the direction of the fitting so that the wear due to the movements of the parts relative to each other is reduced and tacking of the parts to each other due to soilage or corrosion between the parts is practically avoidable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of an anchorage according to the invention secured in a vehicle for a belt buckle,
FIG. 2 shows the vehicle floor end of a second embodiment of the anchorage according to the invention having a short supporting part,
FIG. 3 shows a third embodiment of the anchorage featuring belt webbings,
FIG. 4 is a plan view of a fourth embodiment of the anchorage in which the fitting and supporting part are configured integrally, and
FIG. 5 is a side view of the anchorage shown in FIG. 4.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 an anchorage 10 for a belt buckle 12 is shown. A buckle tongue 14 of a seat belt 16 is latched in place in the belt buckle 12 in the position shown in FIG. 1. At the vehicle floor end 18 of the anchorage 10 the latter is connected by a screw 20 to the frame 22 of a vehicle seat (not shown) extending in the direction X. The anchorage 10 comprises a fitting 24 made up of several leaf springs located one on the other and at the belt buckle end 26 of which the belt buckle 12 is secured. The anchorage 10 includes further an elastically deflectable supporting part 28 which contacts the fitting 24 at the side facing away from the vehicle seat assigned thereto in a biased condition. The supporting part 28 is also configured as a leaf spring, it being permanently deformed such that it presses against the fitting 24 by its belt buckle end 30 after being secured to the fitting 24 by the common screw 20. The belt buckle end 30 is bowed so that a low-friction line contact results between the supporting part 28 and the fitting 24 in the region of the end 30. By coating at least the supporting part 28 at its end 30 the friction between the fitting 24 and the supporting part 28 is further diminished.
Together the fitting 24 and the supporting part 28 constitute a leaf spring pack whereby the fitting 24 and the supporting part 28 may each constitute a separate leaf spring or be made up of a separate leaf spring pack. As a result of the number of leaf springs each located on the other, their dimensioning and their material selection, the bending resistance moment of the anchorage 10 in the direction X, i.e. in the direction of the vehicle seat, and in the direction Y, i.e. in the direction away from the vehicle seat can be selected as desired. Since the supporting part 28 is connected to the fitting 24 only at the vehicle floor end 18 and contacts the fitting 24 at the belt buckle end 30, the supporting part 28 counteracts any bending of the anchorage 10 only in the direction Y, but not in the direction X. In the direction Y the supporting part 28 stabilizes the position of the fitting 24 so that a vehicle occupant when buckling up is able to more easily latch the buckle tongue 14 in the belt buckle 12, due to it being unable to be moved laterally. The pliancy of the fitting can thus be designed high enough to allow an optimum run of the belt webbing to materialize when the belt is buckled up.
In the embodiment shown in FIG. 2 the supporting part 28 is configured relatively short so that the lever arm H from the middle of the screw 20 to the line touching the belt buckle end 30 is smaller than in the case of the embodiment shown in FIG. 1. As a result of this a lesser bending resistance moment of the anchorage 10 materializes in the direction X than in the case of the embodiment shown in FIG. 1.
The embodiment of the anchorage shown in FIG. 3 differs from those of FIGS. 1 and 2 by the fitting 24 comprising two supporting elements 32, 34 oriented essentially parallel to each other, between which a loop of belt webbing 36 extends which, on the one hand, runs through a lug 38 molded to the belt buckle 12 at the belt buckle end and, on the other, through a lug 40 at the vehicle floor end.
On the side of the supporting element 34 facing the direction Y the supporting part 28 contacts the supporting element 34 pretensioned. The screw 20 serves as a common fastener element for the supporting part 28, the supporting element 34, the lug 40 and the supporting element 32 to attach the thereby resulting anchorage 10 to the vehicle seat frame 22 or directly to the vehicle floor. The belt webbing 36, the opposing sides of which are secured to each other between the lugs 38 and 40, receives the tensile force generated in a retraction case in the seat belt 16 whilst the supporting elements 32, 34 hold the belt buckle in the upright position. In this embodiment the pliancy of the anchorage 10 in the direction X is particularly high.
In the embodiment shown in the FIGS. 4 and 5 the anchorage 10 has all-in-all the shape of a three-pronged fork, the middle, longer prong of which forms the fitting 24 and the outer prongs of which are joined to each other at the belt buckle ends 30 by a bridging section 42. This bridging section 42 which forms an elongation of the two-part supporting part 28 contacts the fitting 24, as is evident from FIG. 5. The anchorage 10 shown in FIG. 4 is preferably a stamped item of an originally flat spring sheet metal, to which merely the bridging section 42 needs to be fastened. Since the supporting part 28 without the bridging section 42, and the fitting 24 are originally located in a single plane, from which due to provision of the bridging section 42 the supporting part 28 protrudes, the bridging section 42 is always in contact with the fitting 24 in a biased condition without it necessitating a permanent deformation of the supporting part 28.
The anchorage 10 shown in the FIGS. 4 and 5 may be configured single-layer or be made up of several stampings located one on the other so that a leaf spring pack results.
For installing the anchorage 10 an opening 44 is provided at the vehicle floor end 18, and for securing the belt buckle 12 tappings 46 are provided at the belt buckle end 26.
In this embodiment too, the bending resistance moment is high in the direction Y, i.e. away from the vehicle seat, due to the supporting part 28, whereas in the direction X it is relatively low.
For reasons of better appearance and safe handling, the anchorage 10 may be sheathed in shrinkage tubing in each of the embodiments shown.
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An anchorage for a belt buckle arranged alongside a vehicle seat in a seat belt system is characterized by the belt buckle being affixed to the anchorage and having a laterally deflectable buckle head. The anchorage has a flexible fitting to which the buckle head is secured and which opposes a deflection of the belt buckle towards the vehicle seat a lesser resistance than away from it.
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BACKGROUND OF THE INVENTION
Adiletta U.S. Pat. No. 3,053,762, patented Sept. 11, 1962, provides a filter material having a substrate of woven, inert cloth, such as glass, upon which other fibers, such as glass, are deposited in a controlled blend and quantity and locked firmly to the substrate. The resulting sheet material is impregnated with a thermoplastic material such as polytetrafluoroethylene, polytrifluorochloroethylene or a silicone-type resin to impart special characteristics to the material. The material is then dried and cured or fused to fix the impregnant thereon. Several types and thicknesses of woven cloth may be employed as the substrate, and the pore sizes of the material may be predetermined and controlled by the type and amount of glass fibers applied thereto.
Polytetrafluoroethylene and, to a lesser extent, polytrifluorochloroethylene render the substrate hydrophobic, and impart high strength and inertness, as well as resistance to deterioration at elevated temperatures, because of the high softening point of these polymers. Silicone-type resins also impart hydrophobicity to the substrate, and resistance to deterioration at elevated temperatures, after curing of the polymer, but do not impart high strength.
SUMMARY OF THE INVENTION
In accordance with the invention, it has now been determined that both silicone resin prepolymer capable of being cured to a hydrophobic polymer and polytetrafluoroethylene or polytrifluorochloroethylene when applied together impart a hydrophobicity and strength to the substrate that is far more than additive, and is therefore synergistic. A controlled porosity can be obtained, and the resulting product is also inert, so that it is accordingly far superior to the products obtained using either impregnant alone.
The process in accordance with the invention comprises impregnating a porous fibrous substrate with an aqueous dispersion consisting essentially of polytetrafluoroethylene or polytrifluorochloroethylene in an amount within the range from about 2 to about 40%, preferably from about 3 to about 15%, by weight of the emulsion, and a silicone resin prepolymer in an amount within the range from about 0.1 to about 8%, preferably from about 0.2 to about 1%, by weight of the emulsion; and drying the substrate at a temperature above about 525° F. to cure the silicone resin prepolymer, forming a hydrophobic polymer, and sinter-bond the polytetrafluoroethylene or polytrifluorochloroethylene thereto and to the substrate, thereby forming a hydrophobic porous fibrous sheet material that is inert, has a high strength and a high resistance to deterioration at elevated temperature; each of the silicone polymer and polytetrafluoroethylene or polytrifluorochloroethylene synergizing the hydrophobicity and strength imparted to the substrate by the other.
At amounts of polytetrafluoroethylene or polytrifluorochloroethylene in excess of 15%, ranging up to about 40%, and at amounts of silicone resin prepolymer in excess of 5%, ranging up to about 8%, higher strength is obtained, at a trade-off of reduced porosity, without appreciable change in hydrophobicity.
A hydrophobic porous fibrous sheet material also is provided, comprising a substrate of porous fibrous sheet material impregnated with a composition consisting essentially of a polytetrafluoroethylene or polytrifluorochloroethylene and a silicone resin, said polytetrafluoroethylene or polytrifluorochloroethylene being sinter-bonded to the silicone resin and to the substrate, each of the silicone polymer and polytetrafluoroethylene or polytrifluorochloroethylene synergizing the hydrophobicity and strength imparted to the substrate by the other.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The impregnation step of the process of the invention can be applied to a preformed fibrous substrate, such as a woven or nonwoven sheet material, cloth or fabric, web or batt, as well as to the fibrous material of which such sheet material is formed, prior to sheet formation. Thus, for example, the aqueous dispersion can be blended with a slurry of fibrous material, and then formed into a sheet material, as a result of which the sheet material is impregnated by the aqueous dispersion in situ in the course of its formation.
The substrate can be fully or partially impregnated. Under some circumstances, an impregnation extending only part way through the substrate may suffice. The extent of impregnation can be controlled by restricting the impregnation time, or by squeezing, or by increasing the viscosity of the impregnating dispersion.
Slurrying of the fibrous material in the impregnating dispersion can result in a more uniform distribution of the polymers on the fibrous surfaces and in the interstices between the fibers. However, aqueous dispersions of polytetrafluoroethylene or polytrifluorochloroethylene and silicone resin prepolymer have improved wetting characteristics for both hydrophilic and hydrophobic substrates, and it is accordingly possible to impregnate substantially completely all of the open space in such materials, and distribute the impregnant throughout the pores. Frequently, complete impregnation is difficult when the base material is of a hydrophobic fibrous material, because such materials tend naturally to repel hydrophilic materials, such as aqueous dispersions of the impregnants employed in the process of the invention, and restrict their entry into the pores, especially when the pores are of microscopic dimensions. However, an aqueous dispersion of both of these polymers appears to have better wetting properties for such materials than aqueous dispersions of either impregnant, taken alone.
The fibrous material to which the process of the invention is applicable can be any fibrous material that can withstand heating to 650° F. and higher, according to the curing temperature selected. The material can be hydrophilic, such as glass and quartz, or hydrophobic, such as mineral wool, stainless steel, silica, titania, carbon and boron oxide fibers. These fibers can, as indicated, be loose, and also dispersed in the aqueous suspension of the impregnants, from which slurry the sheet material can be formed by laydown on a Fourdrinier wire or other web-forming procedure, as well as preformed into a woven or nonwoven sheet material. The woven materials can be woven in any type of weave, such as square weave, twill weave, and Dutch twill weave, and also include knotted and knitted materials.
The substrate can have one or several layers of the same or different fibrous material. A particularly preferred substrate is a woven cloth or textile to which is applied loose fibrous material, as in the composites of U.S. Pat. No. 3,053,762. In this case, a woven glass cloth with glass fibrous material attached thereto is a preferred type.
Any polytetrafluoroethylene or polytrifluorochloroethylene polymer can be used. The material should be in finely-divided form, and preferably as an aqueous dispersion. Emulsifiers and wetting agents can be incorporated in the dispersion, to improve its stability, and to improve the wetting of the substrate, particularly where the substrate is of hydrophobic material.
Any silicone resin prepolymer i.e., a silicone resin in a partially polymerized state, or in an incomplete stage of polymerization, can be used, and cured in situ optionally with the aid of a catalyst, after application to the substrate. The material should be in finely-divided form, and preferably as an aqueous dispersion or emulsion. Emulsifiers and wetting agents also can be incorporated in such aqueous dispersions or emulsions.
Silicone polymers are polysiloxanes, made up of terminal ##STR1## groups attached at each end of a chain of recurring monomer units of the type ##STR2## where: (a) R 1 , R 2 and R 3 are hydrocarbon groups, and
(b) n is a number representing the number of units in the polymer.
Most polymers are of course formed of varieties of species with different n values, and the molecular weight represents an average molecular weight for the types of species present.
As the hydrocarbon groups, aliphatic, aromatic and cycloaliphatic hydrocarbon groups can be used, both unsubstituted and substituted, with inert substituents such as, chlorine, fluorine, nitro, carboxylic ester and hydroxyl groups. Halogen groups if attached directly to the silicon atom are active, but when attached to the hydrocarbon substituent are inert.
A silicone resin prepolymer has a relatively low value of n, with active terminal groups, having a labile halogen or hydrogen atom, and is susceptible of further polymerization by linkage of the terminal ends of small chains together at the reactive sites. Such reactions are favored in the presence of a catalyst and at elevated temperature, and any known catalyst for the reaction can be used.
A silicone resin prepolymer that is preferred because of its ready availability and ease of application is polydimethyl siloxane. However, other silicone resin prepolymers can be used, including polymethylethyl siloxane, polydiethyl siloxane, polydipropyl siloxane, polydihexyl siloxane, polydiphenyl siloxane, polyphenylmethyl siloxane, polydicyclohexyl siloxane, polydicyclopentyl siloxane, polymethylcyclopentyl siloxane, polymethylcyclohexyl siloxane, polydicycloheptyl siloxane, and polydicyclobutyl siloxane.
The polytetrafluoroethylene and polytrifluorochloroethylene polymers are available commercially in the form of aqueous dispersions or emulsions ready for use as impregnants for textile materials, and so also are silicone resin prepolymers, in which case the commercially available dispersions or emulsions also include catalysts for the cure of the polymer after application. Such aqueous dispersions and emulsions are for the most part mutually compatible, and consequently the aqueous dispersions and emulsions for application to a porous fibrous substrate in accordance with the invention can easily be prepared simply by blending two commercially available dispersions or emulsions of each impregnant. If the resin concentration in either or both is too high, the dispersions or emulsions can be diluted with water before or after they are mixed together. Mixtures of polytetrafluoroethylene and/or polychlorotrifluoroethylene polymers and of silicone resin prepolymers can be used, if desired, for special effects.
The dispersion or emulsion can be applied to the substrate by any conventional textile application or treating method, including impregnating by dipping the substrate in a tank or reservoir of aqueous dispersion or emulsion, or by spraying the aqueous dispersion or emulsion on the substrate, or by applying the dispersion or emulsion to the substrate by kissing rolls, or by spreading or coating the dispersion or emulsion on the substrate from a head box, optionally with the aid of a doctor blade. After application, the substrate can be squeezed or pressed, if the amount of take-up is excessive, but normally it is less complicated to simply adjust the concentration of the impregnants in the dispersion so that pick-up of the dispersion obtained in application gives the desired weight of resins per unit volume after drying.
After application of the dispersion or emulsion and impregnation to the desired extent, ranging from about 5% to about 100%, i.e., in a manner such that the substrate is substantially saturated therewith, if the 100% pick-up technique is being applied, or less, if penetration is restricted and/or a squeezing step is introduced, the impregnated material is dried and cured. The curing of the silicone polymer requires application of heat at a temperature in excess of about 250° F. in most cases, but higher temperatures can be used, of 620° F. and higher.
Accordingly, the silicone polymer can first be cured by application of an elevated temperature at or above the recommended minimum.
However, it is also important to sinter-bond the polytetrafluoroethylene or polytrifluorochloroethylene so as to anchor it to the substrate and to the silicone polymer, and this requires that the impregnated substrate be heated to a temperature at or above the softening, melting or fusing temperature of the polytetrafluoroethylene or polytrifluorochloroethylene. Polytetrafluoroethylene sinters at about 620° F. and above, and polytetrafluorochloroethylene sinters at 525° F. and above. Accordingly, the impregnated substrate must also be heated at a temperature above this minimum temperature, for sinter-bonding.
Since the silicone polymer will also cure at this temperature, it is usually most convenient simply to heat the impregnated substrate at a temperature above this minimum temperature for a sufficient time both to sinter-bond both the polytetrafluoroethylene and polytrifluorochloroethylene and cure the silicone polymer. Since the curing of the silicone polymer and the sinter-bonding are both rapid, and are complete usually within a few minutes time, only a short heating is required.
After cooling, the finished product can be rolled up, or cut into selected lengths, and is then ready for use.
The product has a remarkable hydrophobicity, which is retained after repeated wettings, a surprising property that is not found in substrates that are simply treated with polytetrafluoroethylene or polychlorotrifluoroethylene polymer or silicone polymer alone. Silicone polymers tend to retain hydrophobicity until the first wetting, but after that wetting, it is very difficult to restore full hydrophobicity to the substrate, even by heating at an elevated temperature. This is not true of the products of the instant invention, which can be wetted repeatedly, and after drying will be found to have their previous hydrophobicity fully restored.
Accordingly, the products in accordance with the invention are particularly suitable for use as vent filter media in medical applications, where they may be wet through without injury, and when dry will again pass gases but not aqueous liquids. Thus, for example, they are particularly useful as air-admitting or air-discharging vents in intravenous administration apparatus, where, for example, they may be required to permit air to escape from a container, or permit air to enter, without passing aqueous liquids therethrough. They can also be used as urinary bags, and will permit air to escape from the bag as it is being filled, but not the liquid.
Inasmuch as the pore size can be controlled so as to be less than 1 micron, and even less than 0.3 micron, the products also serve as barrier filters for air-borne bacteria. For example, in urinary bags they will permit air to escape, but keep the liquid and bacteria in. In use as a filter across an air vent in an intravenous administration kit, any air that enters through the material will be free of air-borne bacteria.
Because of their high porosity, they are of particular utility as filter media for use in hydraulic systems, gas pump filters, filter presses, light-weight filters (replacing metal screens and porous metal), as well as in filter uses where it is necessary to separate gases from aqueous liquids or other hydrophilic liquids, or hydrophilic liquids from hydrophobic liquids, such as water and oil. Since they are hydrophobic, the materials of the invention will permit hydrophobic liquids to pass through, but will repel and therefore prevent passage of hydrophilic liquids. They are consequently useful as barrier filters in the devices of U.S. Pat. No. 3,520,416 to Keedwell, patented July 14, 1970, No. 3,523,408 to Rosenberg, patented Aug. 11, 1970, and No. 3,631,654 to Riely and Skyles, patented Jan. 4, 1972.
The following Examples in the opinion of the inventor represent preferred embodiments of the invention:
EXAMPLES 1 and 2
A continuous strip of woven cloth of glass or mineral wool fiber about 10 mils thick was carried over the belt assembly 14 of the apparatus shown and described in FIG. 3 of U.S. Pat. No. 3,053,762 as the continuous strip 10 of woven cloth. From the head box 22 was deposited on the cloth a layer 5 mils thick, an aqueous slurry of glass fibers 1.0 mm long and 0.001 mm in diameter, after which the composite was passed over a vacuum box so that the fibers of the slurry were firmly locked onto the cloth, while the slurrying fluid was sucked through the cloth, and withdrawn.
The substrate was divided into two strips and to each of these strips were then applied one of the aqueous dispersions whose composition is given in the following Table I. Each of these dispersions contained polytetrafluoroethylene and silicone resin prepolymer, and the dispersions were prepared by blending commercially available polytetrafluoroethylene aqueous dispersion and aqueous silicone prepolymer dispersion in the amounts required to give the aqueous dispersion whose resin content appears in Table I. The polytetrafluoroethylene dispersion was Du Pont's TEFLON 30B at 8% solids W/W.
The silicone resin prepolymer dispersion was reactive polydimethyl siloxane of 150 cp viscosity plus 5% catalyst in water emulsion to 1% solids.
The dispersions were applied to the glass fiber glass cloth composite by passing the strip through an impregnating bath of the dispersion as shown in FIG. 3 of U.S. Pat. No. 3,053,762. Table I sets out the percent pick-up by weight of the impregnants. The material was then passed through a temperature-controlled oven at 700° F., the passage time being about three minutes, whereupon the silicone resin was cured and the polytetrafluoroethylene sinter-bonded to the resin and to the composite substrate.
Hydrophobicity of the resulting substrate was then evaluated by interposing a 3 cm by 3 cm square piece of the product across the line of upward flow of water under pressure, and the pressure required to force the water through the product was then determined as inches of water column. The results obtained for each of the products appear in Table I.
The porosity of the product after impregnation and before impregnation was also determined by the Gurley test method.
The following results were obtained.
TABLE I__________________________________________________________________________ % Pick-up of polytetra- Gurley Test (secs/vol) % By Weight fluoroethylene % by Porosity Porosity Polytetrafluoro- Silicone weight of the substrate Inches of Water before afterExample No. ethylene polymer plus impregnant Column impregnation impregnation__________________________________________________________________________1 6.5 2.5 19.8 55/60 7.6 20.1/27.72 2.0 0.5 6.2 55/60 8.1 9.8/11.4Control 1 6.5 -- 17.7 30 7.6 24Control 2 2.0 -- 6.2 20 8.1 10Control 3 -- 10.0 * 30 1.3 1.3__________________________________________________________________________ * not measurable, less than 1%
It is apparent from the results for the controls that the hydrophobicity of the product containing both polytetrafluoroethylene and silicone polymer is very significantly more than that of the product containing only one of these impregnants, showing that more than additive results are obtained, and that therefore the effect is synergistic.
EXAMPLES 3 and 4
A slurry of glass fibers 0.5 micron in diameter was prepared then formed on a paper-making machine, thereby forming a glass fiber paper 6 mil thick.
To this paper were applied aqueous dispersions of polytetrafluoroethylene, or silicone resin prepolymer, and of both polytetrafluoroethylene and silicone resin prepolymer prepared by blending the commercially-available aqueous dispersions of these materials described in Example 1 in the amounts required to give the proportions indicated in Table II below.
Application of the aqueous dispersions was in accordance with the technique described in Example 1. The aqueous dispersion was placed in an impregnating bath reservoir, and applied to the glass fiber mat by dipping, passing the mat through the bath as shown in FIG. 3 of U.S. Pat. No. 3,053,762. The impregnated material was then cured and dried at 750° F.
The resulting material was evaluated for tensile strength, for porosity in terms of pressure drop in inches of water column, and for hydrophobicity in terms of inches of water column, using the test procedures described in connection with Examples 1 and 2.
The following results were obtained:
TABLE II__________________________________________________________________________ % Pick-up of polytetra- % By Weight fluoroethylene % by Tensile Hydrophobicity Polytetrafluoro- Silicone weight of the substrate strength (Inches of Water PorosityExample No. ethylene polymer plus impregnant (g pi) Column) Δp wc/28__________________________________________________________________________Control 3 -- 0.1 0 30 30 1.4Control 4 -- 10.0 0 30 30 1.3Control 5 5 -- 12 400 17 6.03 15 0.1 20 50 36 1.34 5 0.5 11.2 400 76 7.0__________________________________________________________________________
It is apparent from the results that the products containing both polytetrafluoroethylene and silicone polymer were far more hydrophobic than the Controls, and the hydrophobicity was more than additive, as is apparent from comparison of Controls 4 and 5 with Example 4.
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A process is provided for preparing hydrophobic porous fibrous sheet material suitable for use as a filter due to its inertness, strength, resistance to deterioration at elevated temperatures, and porosity, comprising impregnating a porous fibrous substrate with an aqueous dispersion consisting essentially of polytetrafluoroethylene or polytrifluorochloroethylene in an amount within the range from about 2 to about 40% by weight of the emulsion, and a silicone resin prepolymer such as a reactive polydimethylsiloxane in an amount within the range from about 0.1 to about 8% by weight of the emulsion; and drying the substrate at a temperature above about 525° F. to cure the silicone resin prepolymer, forming a hydrophobic polymer, and sinter-bond the polytetrafluoroethylene or polytrifluorochloroethylene thereto and to the substrate, thereby forming a hydrophobic porous fibrous sheet material that is inert, has a high strength, and a high resistance to deterioration at elevated temperature; each of the silcone polymer and polytetrafluoroethylene or polytrifluorochloroethylene unexpectedly synergizing the hydrophobicity and strength imparted to the substrate by the other. A hydrophobic porous fibrous sheet material also is provided, comprising a substrate of porous fibrous sheet material impregnated with a composition consisting essentially of polytetrafluoroethylene or polytrifluorochloroethylene and a silicone resin, said polytetrafluoroethylene or polytrifluorochloroethylene being sinter-bonded to the silicone resin and to the substrate, each of the silicone polymer and polytetrafluoroethylene or polytrifluorochloroethylene synergizing the hydrophobicity and strength imparted to the substrate by the other.
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This application is a Continuation-in-Part of application Ser. No. 08/871,773, filed Jun. 9, 1997.
NOTICE OF COPYRIGHT
A portion of the disclosure of this patent document contains material that is subject to copyright protection and to which a claim of copyright protection is made. The owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention relates to information retrieval, and the application and deployment architecture for such information retrieval. Specifically, the present invention concerns a multi-tier client/server model for record retrieval wherein optimum record retrieval from a database is achieved based on embedded expert judgments linked to words, phrases, sentences and paragraphs of text; or numbers; or maps, charts, and tables; or still pictures and/or graphics; or moving pictures and/or graphics; or audio elements (hereinafter sometimes collectively referred to as the “links” or “Linked Terms,” or when any one of the aforementioned elements are used singly, as the “link” or “Linked Term”), contained in documents on a network resource, such as a web site and incorporating an intuitive graphical user interface (GUI) to correlate through a plurality of frames or inline frames, dynamic framesets, layers or adding to the display a plurality of fixed or floating pop-up windows, or any combination of the foregoing the retrieved records with records from one remote database or a large collection of remote databases maintained by one company, called a Data Warehouse, plus means to select various databases or Data Warehouses and a comprehensive selectable index of the linked embedded expert judgments.
BACKGROUND OF THE INVENTION
“Pull” Technology
A conventional information retrieval system includes a database of records, a processor for executing searches on the records, and application software that controls how the retrieval system, such as a database management system (DBMS), accepts the search queries, manages the search, and handles the search results. Generally, the database includes records such as text documents, financial or court records, medical files, personnel records, graphical data, technical information, audio and video files or various combinations of such data. Typically, a user enters a password and client billing information, and then initiates the search by finding the appropriate database or groups of databases to search and formulating a proper query that is sent to the DBMS. This process is known as searching by pull technology. To effectively search and retrieve records from the database, the DBMS typically offers a limited variety of search operations, or query models, specifically designed to operate on the underlying records in the database. The query models are coordinated and executed by an application generally referred to as a search engine. For example, a document database, such as a database of court opinions, may be organized with each court opinion as a record with fields for the title of the case, jurisdiction, court and body text. A simple search engine may support a full text searching query model for all the text fields, individual field searching, such as searching by court or jurisdiction, and various Boolean search operations such as and, or, and not. More sophisticated search engines may support the following query models:
1. nested Boolean or natural language searches;
2. grammatical connectors that search for terms in a grammatical relationship such as within the same sentence or paragraph (e.g., “/s”, “/p”, etc.);
3. proximity connectors that require search terms to appear within a specified number of terms of each other (e.g., “w/5”);
4. exclusion terms (“BUTNOT”);
5. weighted keyword terms;
6. wildcards;
7. specification of the order in which the database processes the search request (e.g., grouping words in parenthetical expressions);
8. restriction of the search to certain fields, and formulation of a restricted search such as by date, subject, jurisdiction, title, etc.; and
9. combination of the fields of search.
In addition, large commercial database providers, such as BLOOMBERG, DIALOG, LEXIS/NEXIS and WESTLAW typically have thousands of individual databases. These large commercial database providers are Data Warehouses, which comprise an architecture and process where data are extracted from external information providers, then formatted, aggregated, and integrated into a read only database that is optimized for decision making. Users subscribe to the Data Warehouses by monthly or yearly subscription, and then typically pay stratified levels of hourly charges for access to certain databases, or groups of databases. More recently, Data Warehouses have been selling their content over the Internet by individually pricing each article or document. This is known as “by the drink” pricing since the user does not subscribe to a service over time, but buys only the article s/he wants at one time.
Drawbacks of Pull Technology
One limitation of existing information retrieval systems, especially among the commercial Data Warehouses, is the burden on the user to first enter client and billing information and passwords to gain access and initiate the search, and then formulate the search query. Typically, the subscription based commercial database services provide password administration and extensive catalogues, both in print and on-line, describing the content and scope of the databases offered, and in some cases, live assistance by telephone by reference librarians who assist the user to find the proper databases. However, the user must remember the password, and spend time finding the proper database by catalogue, on-line access, or phone, or else incur more expensive hourly charges searching through single databases or groups of databases for the appropriate database content and scope.
A second limitation of pull technology is the formulation of the search query. To use the more powerful commercial Data Warehouses effectively, a user must be trained to use all of the aforementioned query models, and have sufficient knowledge of the topic to choose the appropriate keywords or natural language terms. The complexity of the search process compels the commercial Data Warehouses to offer training and keyword help to their subscribers by multiple publications that describe search tips; interactive software based training modules; account representatives who visit the user and train him or her; and customer service and reference librarians available by phone.
A third limitation of pull technology concerns how it is employed on the World Wide Web area of the Internet (“WWW”) by such search engines as THE ELECTRIC LIBRARY, EXCITE!, FOUR ONE ONE (411), HOTBOT, INFOSEEK, LINKSTAR, LYCOS, MAGELLAN, ALTA VISTA, OPEN TEXT INDEX, WEB CRAWLER, WWWWORM, and YAHOO!, just to name a few. These search engines' query models are beginning to approach the sophistication and complexity of those of the commercial database companies, but unlike the commercial databases, they offer minimal customer support. Another drawback of the Internet search engines, well documented in the computer business and popular press, is that their search engine algorithms cause multiple irrelevant responses to a query. Other drawbacks of Internet search engines employing pull technology include:
1. The great majority of the Internet search engines have no control over the records in their database. Unlike the commercial Data Warehouses who have an ongoing relationship with the content provider (usually by a license agreement), and who carefully screen, cleanse and format the information provided by their information providers, many Internet search engines sweep through the WWW periodically and automatically, and catalogue web sites as records in their databases. They also permit any web publisher to submit his or her web site as a record entry with little or no prior screening.
2. As a result of little or no screening, and absolutely no contact with the information provider, Internet search engines often provide search results that have multiple “dead ends,” the result of links which are often moved or deleted after the search engines have catalogued them. Moreover, the web sites' authors can sometimes manipulate the words on their site and cause the Internet search engines to list their websites higher on the search engine's relevancy lists than other web sites.
3. The search engines' databases include only a fraction of the Internet's content, and even then, the content may be from dubious sources, or sources which are not updated frequently.
4. Where the web sites include embedded search terms in links in documents to existing Internet search engines or current awareness “news” databases, since the words are linked to the free Internet search engines discussed above, the information retrieved, for reasons explained above, is not reliable and users often receive multiple irrelevant responses. Words linked to the current awareness databases receive more useful information, but there is no GUI correlating and synchronizing the records of multiple databases. Typically, those web sites pass authentication information by the QUERY_STRING environment variable. Once placed on the command line by the browser, the viewer can see all passwords and user names in the authentication argument.
The considerable logistical and practical drawbacks of pull technology are illustrated in the following example of an investment banker who is responsible for buying bonds for an institutional investor, such as a bank or an insurance company. This hypothetical investment banker, based on an actual person, will be used at different points throughout this patent application to illustrate and support the novelty and unobviousness of the present invention.
Every week, this investment banker must go before a board of executives at this bank and provide them with a list of bonds that he had examined and analyzed and recommends to the bank to buy. In order to do his due diligence he must cover in his report five areas of research concerning the bond: (1) compare the bond price to other bond prices (the Bond Comparables); (2) obtain historical data concerning the bond and the company issuing the bond (the Historical Data); (3) obtain the Securities and Exchange filings, such as 10K's, and 10Q's for the company issuing the bond (the SEC Filings); (4) obtain specific information from a wide variety of publications concerning the industry in which the company operates (the Industry Data); and (5) obtain information concerning the historical and anticipated performance of the company's stock (the Stock Data). Furthermore, he has to read various newsletters and white papers issued by investment banks desiring to sell the bonds to him, and which analyze the bonds using the same criteria mentioned above. In order to collect the data, this investment banker must log on and enter password and billing information; find the appropriate databases; and formulate the search and obtain the results in three to five different Data Warehouses, each of which are organized differently from one another and have different methods to enter search queries, and different query models. While pull technology satisfies the demands for the breadth and depth of the search (since the user can formulate his or her own queries, and make unlimited selections of databases to search) it is time consuming, cumbersome and expensive because the user must find the appropriate query formulation and database or databases within which to run the query, sometimes even in different Data Warehouses.
“Push” Technology
In response to the flood of information facing the typical Internet viewer under the pull model, the complexity of the query statements, and the well documented inability of the Internet search engines to locate and deliver relevant content, software companies developed software agents to push information to viewers. The push model is also known as webcasting.
Underpush, computers sift through large volumes of information, filtering, retrieving and then ranking in order of importance articles of current interest. The viewer fills out a “profile” (also called a “channel”), that defines a predefined area of interest or activates a filter. This, in turn, causes the webcast search engine to search its own databases, or the databases of others, for content matching the profile or the filters submitted by the viewer. The viewer, in order to access the channels and have the content “pushed” to him or her, must download special client software which acts either independently of, or in conjunction with, the viewer's browser. Alternatively, a viewer can access a dynamically generated web page on the webcaster's server that lists the found articles. (An example of a dynamically generated web page is “Newspage Direct” by Individual, Inc.)
One early version of the Internetpush model, developed by Pointcast Inc., clogged the network behind a corporation's firewall when large numbers of the employees' software agents pulled information from Pointcast's servers on the Internet at or near the same time. Pointcast later alleviated this problem by providing remote servers that could operate behind a company's firewall and request and collect (or cache) information at once or at predetermined times from the Pointcast severs on the Internet. These intermediate servers then pushed the information to employees, which effectively centralized the distribution of information in the Information Services (IS) department.
As mentioned above, all push technology requires that users compile a “profile” to detail their interests. The prior art of delivering the information obtained by the search engine pursuant to the profile is divided into three broad categories: offline browsers; e-mail delivered content providers and information channels.
The offline browsers typically operate by requiring a user to complete a profile with predetermined categories; automatically search the Internet for the information specified in the profile and download the materials to the user's hard drive for viewing at a later time when the user is off the Internet. This first category of products include: Freeloader by Freeloader, Inc.; Smart Delivery by FirstFloor, Inc.; WebEx by Traveling Software, Inc.; WebRetriever by Folio Inc. and WebWhacker by ForeFront Group, Inc.
The second category of push products delivers the results of searches performed pursuant to the user's profile directly to the user's e-mail box, and includes: Netscape's Inbox Direct and Microsoft Mail.
The third category of push products arranges the predetermined categories into “channels” and uses filters to allow users to customize their news deliveries from a broad range of proprietary news sources. It is claimed that the results of the searches are pushed or “broadcast” in real time to the viewer. Examples of this type of service include: BackWeb by BackWeb, Inc.; Headliner by Lanacom, Inc.; Incisa by Wayfarer, Inc.; Intermind by Intermind, Inc.; Pointcast by Pointcast, Inc.; and Marimba by Marimba, Inc. However, since the retrieved data is first cached on the service provider's server (e.g., Pointcast's server), and then again on the company's servers behind the firewall, the results of the search are not really “broadcast in real time.”
There is a fourth category of push products which do not fall neatly into any of the above three categories of delivery. Citizen 1 by Citizen 1 Software, Inc., is a human organized hierarchical listing of free Internet search engines. The user can then select a number of databases which fall under that category, and run several simultaneous queries in the databases. Digital Bindery by Digital Bindery Company allows users to “subscribe” to web pages as they browse. Once a subscriber, the user will automatically receive via e-mail any updates to the web pages to which the user subscribed.
Webcasting attempts to eliminate the inefficiencies of pull technology, namely the time consuming and unproductive hunt for information through Internet search engines. Instead of an open ended search through many databases linked to the web by various search engines, as is done under the pull model, push substitutes one central secure database which has collected either the content itself, or the links to the content. However, in spite of the name, push, the information provider does not drive the distribution of data. Instead, a client (in a client/server arrangement) contacts the information provider and requests the information. The client then downloads the information in the background, giving the impression that it is broadcast, when in fact, it is only automatically downloaded at a predetermined time.
Shortcomings of “Push” Technology
“Push” may be a satisfactory method for serving information to knowledge workers who depend on a constant stream of updated factual information served in narrow categories. Examples of these kinds of workers would be sales representatives who must find new prospects, staff in field offices who must be aware of sudden price changes, information managers who must distribute software upgrades and marketing professionals who must be aware of the new products released by the competition.
However, there is a category of knowledge workers whose information needs are not properly satisfied by push technology. The hypothetical investment banker discussed above is an example of such a knowledge worker. These knowledge workers cannot use “filters” and “profiles” to provide the most relevant information since the information they need cannot easily fit into categories, but rather spans categories. These knowledge workers use information to solve problems that are rarely alike. They need information to solve a problem, but they do not know what they need day to day.
This knowledge worker culls information and sparks creativity by comparisons and contrasts, juxtapositions, and induction and deduction, rather than by looking at raw news reports. The investment banker discussed above, usually does not know well in advance what industry or company he will be analyzing. He also does not always know where his research and analyses will take him, or what databases he will use. His decisions are tied into so many variables that exist in the marketplace that his information cannot be predetermined by a general form or profile. A further limitation of webcasting is that it has not struck the optimum balance between burdening the viewer with a persistent stream of alerts versus alerting the viewer when new information has arrived.
Moreover, since webcasting centralizes the development, control and the administration of “profiles” within an Information Services (IS) department, certain knowledge workers' information needs may not be satisfied by such centralization. IS departments, already strapped for resources to manage mail servers, web servers, Lotus Notes servers and application servers, may not be capable of managing servers that maintain lists of user “profiles” and dispatch software agents into the World Wide Web (WWW). Thepush model works only if IS departments proactively keep the profile lists current and advertise them internally. Finally, there may be enormous legal ramifications, as of yet not addressed, to corporations downloading copyrighted material to their internal servers and redistributing it internally, especially if the push purveyor links to other websites or search engines without permission. See, “Legal Situation Is Confused on Web Content Protections,“ New York Times , Jun. 9, 1997, at page D5.
Furthermore, all the above examples of “push” technology except for “Digital Bindery”, require the buying, installation, maintenance and updating of software by both the publisher and the user.
In addition to the above-mentioned disadvantages, both the push and pull models fail to address the need to efficiently, inexpensively, and frequently augment web sites with current or historical data. According to the Mar. 11, 1997 Wall Street Journal, in an article entitled At Thousands of Web Sites, Time Stands Still: “Nearly five million pages of a total 30 million indexed by AltaVista on the Web haven't been updated at all since early 1996 . . . . Some 424,000 pages haven't been refreshed since early 1995—and 75,000 Web pages haven't been touched since before 1994:”
Therefore, it is desirable to dynamically augment a static web page containing text, audio, graphics, and/or video information on a network resource with Linked Terms connected to current awareness and/or historical records from expert pre-selected Data Warehouses or single databases, thereby saving the enormous labor and time costs involved in updating web pages.
It is similarly desirable to permit users to choose and narrow their own search criteria through pull technology by clicking on Linked Terms in a written document, and still obtain the benefits of push technology by having current awareness and historical records pushed to update their selections without introducing new protocols or application programmer interfaces (API's) to operate. It is therefore desirable to provide a method and apparatus, use of which does not encumber the user's or publisher's computer system in the following ways: 1) neither the user, nor the publisher have to buy, install, maintain or update software to use the invention; 2) use of the method and apparatus does not require large hard disk and memory allocations by the user; and 3) as a result of “2,” use of the method and apparatus does not preclude using otherpush products simultaneously. This invention can work with any operating system that employs a browser, and can accommodate any binary data type, including FTP repositories, full Java applets and VRML, and any browser plug-in, such as Shockwave applications. Moreover, it can deliver information from a variety of sources, including from the Internet, company databases, groupware and intra- and extranets.
Finally, given the almost exclusive use of current awareness and historical data on databases for research purposes in the prior art, the present invention is unique and unobvious because it is the only invention that updates Linked Terms in any written document, including web pages, with current and/or archived information from databases and Data Warehouses using a proprietary user interface and embedded expert judgment. Updating web pages and written content in this matter effectively transforms raw information into data which can support any point made in any written document. So, for example, if the document is used for marketing purposes, this invention would permit raw information to be used for marketing purposes, etc.
It is also desirable to provide a method and apparatus, which, rather than seeking to identify records on a database whose characteristics exactly match what the user types into a query model, embody one or more kinds of expert judgement data for the purpose of selectively retrieving on demand the best fitting or most appropriate records in response to user data entry. Accordingly, it is desirable to provide a query architecture for an information retrieval method and apparatus that utilizes both pull andpush technologies wherein knowledge workers can select their database resources based on the issue they must solve and current awareness or historical data can be pushed to them based upon embedded expert judgment based on the same issue once they have selected the database resources.
It is further desired that the Linked Terms in any document be augmentative and allow for the efficient integration of embedded expert judgment that correlates a user's choice of a Linked Term with optimum data information judgments or designations to identify those data where the fit between the user's choice of a Linked Term and optimum data for that Linked Term is best.
SUMMARY OF THE INVENTION
Broadly stated, the present invention encompasses a method of dynamically augmenting the contents of file of information on a first network resource, the information file having at least one link, comprising the steps of: creating at least one request corresponding to the at least one link; coupling at least one query argument with the at least one request; sending the at least one request and the at least one query argument to the database, causing the database to search for at least one record that satisfies the at least one query argument; providing a display for viewing by a user; subdividing the display into a plurality of frames or inline frames, dynamic frame sets, layers or adding to the display a plurality of fixed or floating pop-up windows, or any combination of the foregoing; displaying the at least one record that satisfies the at least one query argument in at least a first frame or inline frame, dynamic frame sets, layers or fixed or floating pop-up window, or any combination of the foregoing of the plurality of frames or inline frames, dynamic frame sets, layers or fixed or floating pop-up windows, or any combination of the foregoing; and providing a series of graphic symbols in at least a second frame or inline frame, dynamic frame sets, layers or fixed or floating pop-up window, or any combination of the foregoing of said plurality of frames or inline frames, dynamic frame sets, layers or fixed or floating pop-up windows, or any combination of the foregoing for enabling the user to select one of a plurality of databases.
In a preferred method of the present invention, at least one authentication argument is coupled to the at least one query argument and the at least one request. Furthermore, in a preferred method, the at least one request, the at least one query argument and the at least one authentication argument are sent to the database. The preferred method of the present invention further comprises subdividing the display into a second plurality of frames or inline frames, dynamic frame sets, layers or adding to the display a plurality of fixed or floating pop-up windows, or any combination of the foregoing to replace the plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing and providing a list of index terms in at least one frame or inline frames, dynamic framesets, layers or fixed or floating pop-up window, or any combination of the foregoing of the second plurality of frames, inline frames, dynamic framesets, layers or adding to the display a plurality of fixed or floating pop-up windows, or any combination of the foregoing, where the index terms are for selecting the at least one link in the at least one file of information on the first network resource.
In a preferred embodiment, the at least one request comprises a request header specifying: (a) a purpose of the request; (b) a network address of a second network resource to which the request header is applied; (c) a file name for an application that is stored on the second network resource and (d) an argument that acts as a key in a table lookup, hash table, associative array or linked list on the second network resource; and wherein an application that executes on a second network resource correlates in said table lookup, hash table, associative array or linked list the key with one of a plurality of expert predetermined optimum values, each expert predetermined value comprising a network address for a database, a query argument, and an authentication argument. In a preferred embodiment, the key can be used to create a window display for viewing by a user, the window presenting the user with a menu of choices for further areas of research pertaining to the key. The user, by selecting one of the menu choices, causes the application that is executed on the second network resource to match a key, corresponding to one of the choices in a table lookup, hash table, associative array or linked list, with a request header comprising: (a) a purpose of the request; (b) a network address for a third network resource to which the request header is applied; (c) a file name for an application that is stored on the third network resource; (d) a query argument; and (e) an authentication argument; and causes the application on the second network resource to send the request header to the third network resource.
In another embodiment of the present invention, at least one embedded application is sent from the second network resource to the browser. The embedded application performs one or more of the functions previously performed by the application that is executed on the second network resource in the first embodiment of the present invention such as correlating in the table lookup, hash table, associative array or linked list the key with one of a plurality of the expert predetermined optimum values, or subdividing the display into at least a first frame, window or inline frame, or any combination thereof. The embedded application is preferably an applet,
The present invention also encompasses providing an apparatus for dynamically augmenting the contents of a file of information on a first network resource, the information file having at least one link, comprising: a browser having a display for viewing by a user; a second network resource coupled to the browser, wherein the browser sends at least one request corresponding to the at least one link to the second network resource, further wherein the second network resource couples at least one query argument with the at least one request, the second network resource further causing the browser to subdivide said display into a plurality of frames or inline frames, dynamic framesets, layers or adding to the display a plurality of fixed or floating pop-up windows, or any combination of the foregoing; and a database coupled to the second network resource, wherein the second network resource sends the at least one request and the at least one query argument to the database, the database comprising a search engine for searching for at least one record in the database that satisfies the at least one query argument; wherein the at least one record that satisfies the at least one query argument is displayed in at least a first frame or inline frame, dynamic frameset, or fixed or floating pop-up window, or any combination of the foregoing of said plurality of frames or inline frames, dynamic framesets or layers, or fixed or floating pop-up windows, or any combination of the foregoing and a series of graphic symbols are displayed in at least a second frame or inline frame, dynamic frameset, layer or fixed or floating pop-up window, or any combination of the foregoing of said plurality of frames or inline frames, dynamic framesets, or layers or fixed or floating pop-up windows, or any combination of the foregoing for enabling the user to select one of a plurality of databases.
In a preferred embodiment, the display is subdivided into a second plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing to replace the plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing and a list of index terms are displayed in at least one frame or inline frame, dynamic frameset, layer or fixed or floating pop-up window, or any combination of the foregoing of the second plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing, the index terms for selecting the at least one link in the at least one file of information on the first network resource. Also in a preferred embodiment, the second network resource couples at least one authentication argument to the at least one request and the at least one query argument, further wherein the second network resource sends the at least one request, the at least one query argument, and the at least one authentication argument to the database. The second network resource preferably further comprises a memory for storing a table look up, hash table, associative array or linked list having a plurality of expert predetermined optimum values, each of the expert predetermined optimum value having a network address for a database, a query argument, and an authentication argument, further wherein the at least one request comprises an argument that acts as a key in the table lookup, the key being correlated with one of the expert predetermined optimum values.
In another embodiment of the apparatus of the present invention, at least one embedded application is sent from the second network resource to the browser. The embedded application that is sent to the browser performs one or more of the functions that are performed by the application on the second network resource, such as correlating in the table lookup, hash table, associative array or linked list the key with one of a plurality of the expert predetermined optimum values, or subdividing the display into at least a first frame, window or inline frame, or any combination thereof.
An advantage of the present invention is that it provides a method and apparatus to cost-effectively and dynamically update web pages containing text, audio, graphics and/or video data that are a part of a network resource with Linked Terms connected to current awareness or historical records from expert pre-selected Data Warehouses or single databases, without undue waste of time and labor.
Another advantage of the present invention is that it provides the ability for network users to have access to a large number of electronic database providers (i.e., BLOOMBERG, DIALOG, DOW JONES, LEXIS/NEMS, WESTLAW, etc.) without being limited to a particular proprietary graphical user interface (GUI), entering passwords or billing information or being trained to use the query models for each Data Warehouse.
Yet another advantage of the present invention is that it provides for a wide spread dissemination of information from databases and Data Warehouses without the cost and security problems to the Data Warehouses of training users to use the system or issuing and administering a large number of passwords.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned and related advantages and features of the present invention will become apparent upon review of the following detailed description of the invention, taken in conjunction with the following figures, where like numerals represent like elements, in which:
FIG. 1 is a block diagram of a typical digital computer utilized by a preferred embodiment of the present invention.
FIG. 2 illustrates a simple client/server system of the prior art.
FIG. 3 illustrates a more complex client/server system of the prior art.
FIG. 4 is a block diagram of one embodiment of the information retrieval system of the present invention.
FIG. 5 is a flowchart of a method of operating the information retrieval system of the present invention.
FIGS. 6, 7 , 8 , 9 , 10 and 11 are examples of display screens presented to the user during the operation of the process outlined in FIG. 5 .
FIG. 12 is a flowchart of the method of operating the “Infodex” indexing process of the present invention.
FIGS. 13, 14 , and 15 are examples of display screens presented to the user during the operation of the process outlined in FIG. 12 .
FIGS. 16, 17 , 18 and 19 are example screen shots of the browser windows that are presented to the user after the execution of a function by the user.
DETAILED DESCRIPTION OF THE INVENTION
The present invention overcomes the limitations of the prior art by providing an augmentative query architecture that allows for the creation, addition and subsequent integration of embedded expert judgement and authentication information into a query submitted to an information retrieval system, together with an intuitive GUI designed to correlate through a plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing, the responses of the information retrieval system; a series of graphic symbols for enabling the user to select one of a plurality of databases or Data Warehouses and an index of terms for selecting a link in a file of information which is also referred to below as an information template or a file of data on a first network resource which is also referred to below as a server or Document Server. The invention comprises an information template which is a file of data in Hypertext Markup Language (HTML), or other suitable mark up language, such as Dynamic HTML (DHTML) and Extensible Markup Language (XML) or Wireless Markup Language (WML); or any streaming audio and video multimedia format such as Internet Protocol version 6 (IPv6); Microsoft's Active Streaming Format and Advanced Streamning Format (ASF); Real Audio; MPEG, Layer 3 (MP3); Internet Engineering Task Force (IETF) proposed standard Real-Time Streaming Format; Synchronized Multimedia Integration Language (SMIL); International Telecommunication Union's (ITU) T. 120 standards for data conferencing and videoconferencing and Apple's Quick Time; or any graphics format such as Graphics Interchange Format (GIF); Joint Photographics Experts Group (JPEG or JPG); Portable Network Graphics (PNG); Vector Markup Language (VML) or Precision Graphics Markup Language (PGML) embodying text, audio, graphics, and/or video elements, containing Linked Terms and posted in the preferred embodiment on a HyperText Transport Protocol (HTTP) server (the “Document Server”), which is connected to a network. The information template can be a document specifically prepared for publication on the World Wide Web; a newsletter; white paper; or other document which has been printed, but converted into HTML.
The hypertext links in the information template contain the HTTP or other network protocol addresses to a second HTTP server on a computer network. The second server acts as an application proxy server (the “Application Server”) to both the client application and a third HTTP server on a computer network connected through a database interface application running on a server to a Data Warehouse or database containing multimedia information searchable by the database's or Data Warehouse's proprietary search engine (the “Database Server”). When a user clicks on the hyperlinks appearing in the window of the browser, he or she will be in simultaneous interactive communication with both the Application Server and the Database Server across the network.
The Application Server runs a computer application that uses gateway protocols, such as the Common Gateway Interface (“CGI”). The application includes look-up tables, hash table, associative array or linked list that comprise authentication data for access to, and the network addresses of a plurality of Database Servers. The application will also contain in its look up tables, hash table, associative array or linked list queries (such as Boolean search terms, date and field restrictions and connectors) that have been formulated by expert judgment to return the optimum results from the Data Warehouse's proprietary search engine, and any other necessary information to authenticate a user, gain access to the Database Server, and run a search in the Data Warehouse's search engine. The CGI application on the Application Server will act as a bidirectional conduit between the Application Server and any application on the Database Server that can accept at runtime some form of HTTP data (for example, standard input (stdin) or environment variables such as QUERY_STRING). In another embodiment of the invention, the Application Server instead of using CGI can use embedded Structured Query Language (SQL) commands to pass the query argument directly to the Data Warehouse. In yet another embodiment, instead of using CGI or embedded SQL, one can use object oriented libraries such as Microsoft's Open Database Connections or Sun/Intersolv's Java DataBase Connectivity-Object Database Connectivity (JDBC-ODBC) Bridge to pass the authentication argument and the query argument.
When the user clicks on any one of the hyperlinks contained in the document on the Document Server, the CGI application on the Application Server will automatically return a set of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing described in the HTML, to the browser, to which certain information will be targeted in the frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing by the Application Server, or directly by the Database Server or by both the Application Server and the Database Server concurrently.
As a result of the browser's frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing, and the client's simultaneous connection with the Document Server, Application Server and the Database Server, the user will be able to interactively access a range of expert pre-selected individual databases or databases in Data Warehouses linked to the Linked Terms appearing in the frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing of the browser.
FIG. 1 is a block diagram of a typical prior art computer system 100 utilized by a preferred embodiment of the present invention. Computer system 100 may be a general purpose computer or a specially designed computer having features or capabilities equivalent to those described below in relation to computer system 100 . Computer system 100 comprises an alphanumeric input device, such as a keyboard 120 , coupled to a Aprocessing means, such as a Central Processing Unit (CPU) 140 , such as an Intel Pentium chip. The input device may also be another computer, or other known input devices. An additional user input device 110 for communicating cursor direction or selection, such as a mouse, trackball, stylus, motion pad, or cursor direction keys may be coupled to CPU 140 . CPU 140 is coupled to Read Only Memory (ROM) 142 and main memory 141 , which in a preferred embodiment comprises Random Access Memory (RAM). Additionally, input/output device controller 170 and a bus 150 are coupled to CPU 140 .
Main memory, which may include RAM or some other volatile storage device, is for storing information and instructions to be executed by the CPU 140 . Main memory 141 may also be used to store temporary variables or other intermediate information during execution of instructions by CPU 140 . ROM 142 , which may be replaced by or used in conjunction with some static storage device, is coupled to CPU 140 for storing static information and instructions during processing by CPU 140 . Computer system 100 also comprises hard disk 164 , which is a data storage device that communicates with CPU 140 across bus 150 . Computer readable removable media 172 , such as magnetic or optical disk (including but not limited to magnetic tapes, laser disks, or CD-ROMs or DVDs), may be coupled to an input/output device 171 . Data is read from or written to the removable media by the I/O device under the control of the I/O device controller 170 .
These media may be used for storage of the various files to be described herein including graphic and text files.
Computer system 100 may also comprise an output device 130 , such as a cathode ray tube (CRT) or liquid crystal display (LCD), coupled to the CPU 140 for displaying information to a computer user. In addition, an audio output device 180 which converts digital information to analog information and delivers the output through headphones, speakers, or other well known audio mixing and storage devices such as magnetic tape may be coupled to the bus 150 through the audio adapter 161 . Other devices such as graphic (or video) output devices 181 may also be coupled to the bus 150 via a graphics adapter (or a video accelerator adapter) 162 , which also can send graphic or video output to output device 130 . Network connection or modem 163 , or some other output device (Cable, Digital subscriber Line or Satellite) may also communicate with CPU 140 across 15 bus 150 . Network connection or modem 163 may communicate with other networks, such as the Internet, extranets, intranets or data processing systems 183 across communication line 182 .
It is to be noted that the following discussion of various embodiments discussed herein will refer specifically to a series of routines which are generated in a high-level programming language (e.g., the PERL interpretive language, Java, Active X, C++, etc.) which is interpreted and/or executed in computer system 100 at run-time. These further are used in conjunction with the browser and server software available from Netscape, Microsoft and other producers of graphical browsers that communicate through network protocols such as HTTP, as described above. It is also to be noted, however, that the following methods and apparatus may be implemented in special purpose hardware devices, such as discrete logic devices, large scale integrated circuits (LSI's), application-specific integrated circuits (ASIC's), or other specialized hardware, or implemented by combinations of the computer components with other non-computer components, such as Microsoft's Web-TV, or reduced capacity computers, such as Sun Microsystems, Inc.'s (“Sun Microsystem's”) Network computer, which can consist of a web browser, a network connection, 4MB to 8MB of memory and a display screen. The description here has equal application to apparatus or programming languages having similar function.
FIG. 2 illustrates a simple client/server system of the prior art in which a single, bi-directional communication line establishes a connection between a client and server across a network. The client is an application program that establishes connections over a network for the purpose of sending requests and receiving responses. The server is an application program that accepts connections in order to respond to requests sent by the client. A connection is a transport-layer virtual circuit established between two application programs for the purpose of communication.
In FIG. 2, client 200 is coupled, by a bi-directional connection 201 to server 202 (typically, a remote computer system accessible over the Internet or other network) which can parse an Internet protocol, such as Hypertext Transfer Protocol (HTTP) Client 200 sends requests for information to server 202 by bi-directional connection 201 . Server 202 searches for the requested data in its files, finds and retrieves it, and then presents the data as server responses to the client 200 via bi-directional connection 201 . As server 202 , in a preferred embodiment, operates in an HTTP protocol, it is also referred to as an HTTP document server. HTTP is a communications protocol that supports distributed collaborative information systems over the Transmission Control Protocol/Internet Protocol (TCP/IP) packet based routing system used by the Internet, including TCP/IP version 6.0. It is to be noted that other transport layer application programming interfaces (API's) such as the Component Object Model (COM); Distributed COM (DCOM); IBM's System Object Model (SOM) and Distributed SOM (DSOM) for networks and Java; Microsoft's ActiveX; Common Object Request Broker Architecture (CORBRA) (with enhancements), Sun Microsystem's Java's Remote Method Invocation (RMI) for the Internet, JDBC, Java Interface Definition Language (Java IDL), Java Naming and Directory Interface (JNDI), Java Message Service (JMS), Java Transaction Service (JTS) and Enterprise Java Beans may also be used in the present invention.
HTTP has an open-ended set of methods that can be used to indicate the purpose and location of a request. These methods signal the purpose of a request by using terms such as Simple Mail Transport Protocol (SMTP), File Transport Protocol (FTP), or HyperText Transport Protocol (HTTP). Other methods can use the Uniform Resource Identifier (URI); Uniform Resource Locator (URL); or Uniform Resource Name (URN) to indicate the network resource to which a method is to be applied. A network resource is a network data object or service that can be identified by a URI, URL or URN. An example of a URL is: http://www.example.com/file.html, which provides the address of subdirectory “file.html” on the network resource “www. example. com”. A network resource may also be a server, a database or Data Warehouse.
HTTP can also be used as a generic protocol for communicating with other Internet protocols such as SMTP, Network News Transport Protocol (NNTP), FTP, Gopher or Wide-Area Information Services (WAIS). An HTTP message consists of a structured sequence of octets (a set of eight bits) transmitted by the connection.
FIG. 3 illustrates a more complex client/server system of the prior art. The system shown in FIG. 3 will be used to illustrate the flow of information in a typical academic and research oriented on-line service, such as LEXIS-NEMS. In the case of LEXIS/NEXIS, remote users would pay a yearly subscription fee plus stratified hourly charges to access the Data Warehouse run by this on-line service. To access LEXIS/NEXIS, a user dials in from a remote PC using client 200 , which includes LEXIS proprietary software, and sends requests via the service's closed-access network 205 . Multiple front-end communication servers 210 , which can handle more than 3,000 simultaneous sessions during peak business hours and that run and use proprietary applications and standard and non-standard transport protocols, would feed the queries through a database interface 220 to five large multiple virtual systems (MVS)-based operating system servers, which are collectively designated as Data Warehouse 230 . The Database Interface 220 is also known as a middleware layer. The middleware manages communication and provides application services between the Database Server 211 and the Data Warehouse 230 . The middleware layer can be separate applications running on the Data Warehouse 230 , the Database Server 211 or in a high traffic environment, on a separate application server. LEXIS/NEXIS supplements their MVS systems with 120 UNIX-based servers to manage data. All other on-line services such as DIALOG, WESTLAW and BLOOMBERG have similar setups. LEMS/NEXIS is an example of a Data Warehouse, as that term is used herein.
During 1996, all of the on-line services, including the academic and research oriented ones, migrated in varying degrees to the Internet and the World Wide Web (WWW) or simply the “Web”. It is anticipated that, in order to provide access to the WWW via the Internet transport protocol HTTP, the major research and academic databases, as well as all new database on-line services, will have to integrate HTTP servers into their front-end communications servers, and convert parts of their data stores into HTML, or use interfaces to convert documents into HTML on the fly. Corporate intranets are also switching to the HTTP protocol and will integrate some form of HTTP servers or HTML conversion “on the fly” to access their legacy databases.
By adhering to the HTTP protocol, a standard is developed that reduces and simplifies the variety of interfaces and gateways used by the on-line services and Data Warehouses to provide widespread access to their data stores. This, in turn, makes it possible to interpose an HTTP server as a application server between the client and the database without additional complicated gateways or interfaces. As used herein, a gateway is any application program that receives data from a browser or other HTTP server and converts it into a form the database can understand. An interface is a software application that interacts with a database or Data Warehouse.
FIG. 4 . is a block diagram of one embodiment of the information retrieval system of the present invention. The informational retrieval system comprises a client 203 which is coupled to a Document Server 202 and an Application Server 207 . Active within the client 203 is a first process, known as a browser 204 , which establishes the connection, via the HTTP protocol with remote servers. A browser is an application which runs on a client and which can access a variety of servers providing information, including HTTP servers. The Client 203 is coupled to the Document Server 202 by a bidirectional connection 201 through which client 203 sends requests for information (client requests) to and receives information from the document server 202 as described in relation to the system shown in FIG. 2 . The Client 203 is coupled to the Application Server 207 by an HTTP connection 206 . The Client 203 and the Application Server 207 interactively communicate with each other using the functionality provided by HTTP. The WWW includes all the servers adhering to this standard which are accessible to clients via TCP/IP addressing methods, such as the URL's. For example, communication can be provided over an HTTP protocol used on a TCP/IP network. The client application and server may be coupled via Point to Point (PPP), or Serial Line Internet Protocol (SLIP) for dial up connectivity to the Internet, or by 56 KBPS, ISDN, Frame Relay, Digital Subscriber Line (DSL), Asymmetric Digital subscriber Line (ASDL) or other narrow band, wide band or broad band technology, including T-1, T-2, T-3 or T-4, Wireless, Cable or Satellite for high speed connectivity to the Internet.
Application Server 207 is coupled to a Database Server 211 by connection 208 . Application Server 207 and Database Server 211 interactively communicate with each other using the functionality provided on connection 208 by the Common Gateway Interface (CGI) and HTTP via connection 208 . The Document Server 202 , Application Server 207 and Database Server 211 are typical HTTP servers equipped with varying degrees of memory and hard drive space. At a minimum, an example of a typical installation of each server would consist of a Sun Microsystems Netra workstation running a Solaris 2.5 operating system and employing 32-64 megabytes of memory and 2 gigabytes of hard drive space. The workstation can use the National Center for Supercomputing Applications (NCSA) HTTP daemon or some other comparable software such as Netscape's Enterprise Server as the server software.
Database Server 211 is in turn coupled to a Data Warehouse 230 via Database Interface 220 . The Data Warehouse 230 may include one or more databases. The Database Server 211 acts as a front-end HTTP server to data stored in the Data Warehouse 230 or an individual database.
Applications stored and executed on the Application Server 207 , known as “server side” applications, can use a Common Gateway Interface (CGI) protocol interface; a CGI protocol interface with vendor added extensions such as Oracle's Web Request Broker; a non-CGI programmic object oriented communications protocols interface, such as Java Servlet application programmer's interface (API), Java applets; or non-CGI programmic server extensions, such as Microsoft's Internet Server API, Netscape API, or Microsoft's Active Server Pages (ASP). For example, ASP allows HTML, scripting languages and activation of other software objects on a single web page as a gateway interface to the Data Warehouse 230 or an individual database. CGI interfaces scripts and programs to an HTTP server. CGI details how clients ask HTTP servers to run a program, how HTTP servers activate the program and pass client parameters to it and how the programs send responses back to the client.
Most CGI programs are written in Perl or Python. It is to be noted that, according to the present invention, one of the aforementioned applications on the Application Server 207 , among other things: (1) correlates in a table lookup, hash table, associative array or linked list, a key sent by the browser 204 on client 203 to Application Server 207 with one of a plurality of expert predetermined values (each expert predetermined value comprising a network address for a database or Data Warehouse, a query argument, and an authentication argument); and (2) generates a second request header where the request header comprises a purpose of the request, a network address for a third network resource to which the request header is applied, a file name for an application that is stored and executed on the third network resource, an authentication argument and a query argument, and, if required, modifies a record that satisfies the query argument. Therefore, the application on the Application Server 207 effectively couples a query argument to a request sent by the browser 204 on the client 203 to the Application Server 207 .
Additionally, the application preferably couples at least one authentication argument to the query argument and the request. Additionally, the applications on the Application Server 207 preferably cause the browser 204 to subdivide its display into a plurality of frames or inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing, cause a record that satisfies the query argument to appear in the largest of the frames, inline frames, dynamic framesets, layers or fixed or floating pop-up windows, or any combination of the foregoing, cause a series of graphic symbols, e.g., buttons, to appear in a second frame, inline frame, dynamic framesets, layer or fixed or floating pop-up window, or any combination of the foregoing for enabling a user to manually select one of a plurality of databases or Data Warehouses, cause an excerpt of text that includes a link in a file of information to appear in a third frame, inline frame, dynamic frameset, layer or fixed or floating pop-up window, or any combination of the foregoing, and cause information associated with the source of the file of information to appear in a fourth frame, inline frame, dynamic frameset, layer or fixed or floating pop-up window, or any combination of the foregoing. When the user manually selects one of a plurality of databases or Data Warehouses, the application correlates in a table lookup a key, sent by the browser 204 when the user manually selected the database or Data Warehouse, with one of a plurality of expert predetermined values. Additionally, the applications send the second request header to a third network resource, such as Database Server 211 . Thus, the applications send a request header in response to the selection of the link or a button and match a key corresponding to the link or button with a second header request. Similarly, the applications send the request, the query argument and the authentication argument to the Data Warehouse 230 .
FIG. 5 is a flowchart of the method of operating the information retrieval system of the present invention. At step 249 of the process, the user, employing a browser 204 running on a client 203 (shown in FIG. 4 ), sends a request via a network protocol such as HTTP for an HTML file to the Document Server 202 (shown in FIG. 4 ). A typical HTTP statement is in the form http://www.example.com/file.html. The HTML file “file.html” may be an HTML document that will have words, phrases, sentences and paragraphs, or graphics, video and audio elements, each symbolized by an argument abbreviating the name of the term or client (the “Argument Symbol”). The HTML document may be a document prepared for publication on the WWW (including a Web page), a newsletter, or a white paper or other document which has been printed but converted into HTML. In the example shown in FIG. 5, the Linked Term is the phrase “AUTOMOTIVE-RELATED INDUSTRY,” and the Argument Symbol that is assigned to it is “AR 1 ”. An HTTP network address in the form of http://.Aww.example com/datasite.pl is employed, where “http” is the purpose of the request, “www.example.com” is the address of the Application Server and “datasite.pl” is the name of a CGI application on the Application Server 207 (shown in FIG. 4 ). The Argument Symbol is added to the end of the HTTP network address after a question mark as shown in FIG. 5 where “AR 1 ” follows the question mark, “?”. The HTTP network address and the Argument Symbol, “AR 1 ,” constitute the request corresponding to the Linked Term, “A UTOMOTIYE-RELATED INDUSTRY”. The request comprises a request header specifying a purpose of the request (“http”), the network address of Application Server 207 to which the request header is applied (“www.example.com”), a file name of an application that is stored on Application Server 207 (” datasite.pl”), and an argument that acts as a key in a table lookup and corresponds to the request (“AR 1 ”). When the user clicks on the Linked Term, “AUTOMOTIVE-RELATED INDUSTRY”, it is determined at step 251 whether the user must be authenticated. Thereafter, if there is a need to authenticate the user, the user is authenticated, in a first authentication process, by the Application Server at step 252 before proceeding to step 253 . Otherwise, the process is continued at step 253 without the first authentication. Thereafter, the browser passes the request, including the Argument Symbol, to the CGI application on the Application Server 207 (shown in FIG. 4 ). For example, if the term AUTOMOTIVE-RELATED INDUSTRY is linked to three separate Database Servers, there will be three Argument Symbols AR 1 , AR 2 and AR 3 assigned to the term where each Argument Symbol contains the separate network address of each one of the Database Servers. Although FIG. 5 uses as an example Argument Symbols A 1 . . . A 10 , there is in reality no limit to the number of databases to which a Linked Term can be connected, and therefore FIG. 5 should not be construed as a limitation.
The Argument Symbol is used as a key in a table lookup on the Application Server that is implemented as a hash table, associative array or a linked list. The table look up matches the key with the expert-predetermined optimum values for the Database Servers' network address and query.
Thus, browser 204 sends a request to Application Server 207 (shown in FIG. 4 ). The request comprises a request header which specifies the purpose of the request, the network address of the Application Server 207 , the file name of an application that is stored on the Application Server 207 , and an argument that acts as a key in a table lookup and corresponds to the Linked Term associated with the request. In a preferred embodiment, the request, including the request header, is sent to the Application Server 207 via a collaborative information systems transmission protocols used on a network which include a combination of Hypertext Transfer Protocol (HTTP) and Transmission Control/Internet Protocol (TCP/IP), including TCP/IP version 6.0.
Alternatively, the argument that acts as a key or the key can be used to create a pop-up or floating window display for viewing by the user. The window display presents the user with a menu of choices for further areas of research pertaining to the key and, therefore, the Linked Terms. Each choice corresponds to an Argument Symbol. The user chooses one of the options presented, which will send an Argument Symbol to Application Server 207 that is used as a key in a table lookup on Application Server 207 . The table lookup then matches the key with one of a plurality of expert-predetermined optimum values used to retrieve records from the Data Warehouse or database. Each expert predetermined optimum value includes a network address for the Database Server, a query argument, and an authentication argument. In other words, the user by selecting one of the choices causes an application that is executed on Application Server 207 to match a key, corresponding to the selected choice in the table lookup, with a request header comprising a purpose of the request, a network address for a database network resource to which the request header is applied, a file name for an application that is stored on the database network resource, a query argument and an authentication argument. Additionally, the selection of the choice by the user causes the application that is executed on Application Server 207 to send the request header to the database network resource, e.g., Data Warehouse 230 or a database.
Next, the CGI application is executed, as shown at 253 . At step 254 , the CGI application finds and sends to the browser the file which contains the HTML code that causes the browser to subdivide its main viewing window into a series of frames 262 , 263 , 264 and 265 or inline frames, or fixed or pop-up windows, or any combination thereof. Simultaneously, at step 255 , the CGI application correlates the Argument Symbol with the network address of the Database Server and the query argument chosen to be inserted in the database's or Data Warehouse's search engine, and sends a request header to the Database Server 211 (shown in FIG. 4 ). An authentication argument (e.g., a user name and password) and a query argument are coupled to the request (which includes a request header) corresponding to the Linked Term selected by the user. The request header includes a purpose of the request (e.g., http), a network address of the network resource to which the request header is applied, a file name for an application on the network resource to which the request header is applied and alphanumeric arguments that contain the user ID; password and search query 255 . (The authentication argument is used to access a database or Data Warehouse that may require authentication prior to allowing access to files or records in the database or Data Warehouse.) Thereafter, the request header, the authentication argument and the query argument are sent to the database or Data Warehouse. In another embodiment, the request header, the authentication argument and the query argument are sent to the Database Server associated with the database or Data Warehouse. Thereafter, the Database Server passes the request header and sends the authentication argument and the query argument to the database or Data Warehouse. If the Database Server performs the authentication, then just the query argument will be sent to the database or Data Warehouse. The Database Server takes the query argument and passes it through the Database Interface 220 (shown in FIG. 4) to the Data Warehouse 257 . The Data Warehouse search engines locate the records and send them back through the Database Interface 220 (shown in FIG. 4) and the Database Server 211 (shown in FIG. 4) to the CGI program 261 on the Application Server for further processing, which will be described below.
FIG. 6, shows the resulting view in the browser as a consequence of the Document Server's response to a user's request for a document. Browser window 300 is the initial screen of the document sent by the Document Server 202 (shown in FIG. 4 ). Browser window 301 shows the same document after the user scrolls down to a Linked Term 303 he or she wants to see. In one embodiment of the invention, such as that shown in FIG. 6, the hyperlinked term can have hyperlinked symbols 305 following immediately after the term which indicate to the reader the properties of the media linked to the Linked Term. For example, a “speaker” symbol will indicate audio content, a “film strip” segment symbol will indicate video and a “document” symbol will indicate text. These symbols could appear singly or in groups depending on the nature and properties of the content connected.
FIG. 7 shows a view of the browser window after it has been divided into four frames. When the user clicks on the Linked Term, the browser sends a request to the Application Server. All or only some of the frames may be scrollable in either an up and down direction, or in a side-to-side direction. The Application Server responds by outputting HTML <FRAMESET> and <FRAME> elements that are described in the CGI application on the Application Server causing the browser's windows to subdivide into four frames 400 , 401 , 402 , and 403 and 254 , 262 , 263 , 264 and 265 (shown in FIG. 5 ). It is to be noted that the present invention is not limited to subdividing the browser's window into four frames, as shown in FIG. 7 . Therefore, in the other embodiments, the browser's window may be divided into any number of frames arranged in any desired way or by inline frames, or by adding to the browser's window a plurality of fixed or pop-up windows, or any combination thereof
For instance, as a result of clicking on the link “AUTOMOBILE-RELATED INDUSTRY”, the browser sends the request header http./Avww.example.com/datasite.pl?AR 1 to the Application Server located at the network address “www. example.com”. The Application Server parses the incoming request, and locates the CGI application “datasite.pl”. The Application Server then executes “datasite.pl” and outputs HTML <FRAMESET> and <FRAMES> element to the browser 254 (shown in FIG. 5 ), causing the browser to parse the HTML element. As the browser parses the HTML elements, it causes the main viewing window in the browser to subdivide into four frames 400 , 401 , 402 and 403 . The characteristics of the frames' functionality are as follows:
Each frame can load a network address independently of the other frames;
Each frame can be given a specific name (using the HTML “NAME” tag), allowing it to be targeted by other request headers;
Each frame can resize itself dynamically in response to changes in the size of its visible area, or it can be set to disallow dynamic resizing or manual resizing by a viewer; and
The frames can either be standard fixed frames or floating frames.
Each frame may be set to scroll or not to scroll.
Each frame may be an inline frame.
In addition to the frames, the HTML code sent to the client specifies text, audio, graphics or video files (or documents) or some combination thereof, to be pulled in from other directories on the Application Server, and/or from other remote servers across the Internet or within an intranet, and into predetermined nested frames on the client application. The HTML code in the CGI application on the Application Server which calls for the documents from the Database HTTP Server can specify the frames to which the file would be loaded by using the TARGET element and specifying the attribute given to the frame's NAME element.
For example, when the HTML code sent by the CGI application on the Application Server loads into the browser, it may contain a FRAMESET tag, which is nested within a second FRAMESET tag, which is further nested within a third FRAMESET tag.
Each FRAMESET tag is placed in the space that would be used for the corresponding frame if it had been a FRAME tag instead of a nested FRAMESET. When the browser parses the HTML code from the Application Server, the browser will first divide the browser's window into two separate frames in a 78% to 22% ratio (the 78% window is 400 and the 22% window is the sum of the areas of 401 , 402 and 403 ). Next, the browser will subdivide the 22% window into a 47% to 53% ratio (the 53% window is 402 and the 47% window is the sum of the areas of 401 and 403 ). Finally, the 47% window is further subdivided into a 72% to 28% ratio (the 72% window is 401 and the 28% window is 403 ).
FIG. 8 shows frames 1 to 4 of the browser's window filled with multimedia content received concurrently from both the Proxy Server and the Database Server 258 , 259 , 260 and 261 (shown in FIG. 5 ). Frame 1 500 is identified with a named attribute of the FRAME element such as NAME=frame 1, where “frame 1” is the attribute of the element “name”. In the present invention, the FRAME element located within the CGI application (“datasite.pl”) on the Application Server holds the SRC element (see example below) for the hyperlink, and passes to the Database Server the authentication argument (password and user ID) and the query argument for the Data Warehouse's search engine through a QUERY_STRING environment variable annexed after the “?.” The NAME attribute refers to the name of a particular frame (frame 1, frame 2, etc.), and the HTML document referred to in the SRC element is automatically loaded into that named frame. So, the results of the search called for by the SRC element below would be loaded into frame 1 500 .
The FRAME elements within the nested FRAMESETS located within datasite.pl look like this: <FRAMESET ROWS=“78%,22%”>
<FRAME
SRC=“http://www.database.com/directory 1/CGI.pl? userlD=X & password=Y & SEARCH=Z
<FRAMESET ROWS=“47%,53%”>
<FRAMESET COLS=“72%,28%”>
<FRAME
SRC=“up1-a1˜1.html” NAME=“frame2” MARGINWIDTH=“1” MARGINHEIGHT=“1” SCROLLING=“NO”>
<FRAME
SRC=“cibc12˜1.html” NAME=“frame4” MARGINWIDTH=“1” MARGINHEIGHT=“1” SCROLLING=“NO”></FRAMESET>
<FRAME
SRC=“lnk-12˜1.html” NAME=“frame3” MARGINWDTH=“1” MARGINHEIGHT=“1” SCROLLING=“AUTO”></FRMASET>
<NOFRAMES>
where “www.database.com” is the URL of the database; “directory 1” is the directory on the server where the CGI application is located; “CGI.pl” is the Data Warehouse's CGI application located on the Database Server and X, Y and Z are the alphanumeric arguments that contain the user ID, password and search query, respectively, and which are passed to CGI.pl by the QUERY_STRING environment variable. The contents called for by the SRC hyperlink “www. database. com” are automatically loaded into frame 1 500 ; 261 and 262 (shown in FIG. 5 ). Likewise, the contents called for by the SRC hyperlink up1-a1˜1.html would be loaded in frame 2 501 ; 258 and 263 (shown in FIG. 5 ); the contents called for by the SRC hyperlink cibc12˜1.html would be loaded in frame 4 503 ; 260 and 265 (shown in FIG. 5) and the contents called for by SRC hyperlink Ink-12˜1.html would be loaded in frame 3 502 ; 259 and 264 (shown in FIG. 5 ).
It is to be noted that a second environment variable, such as PATH_INFO, can be used to pass data to the CGI.pl application. Furthermore, one can also use METHOD=POST, and pass the data by stdin and “stdout” in the same fashion. Since the CGI application (datasite.pl), and not the browser, makes the request to the Database Server, the user will not see either the passwords or user ID's on the command line of the browser if the QUERY_STRING environment variable is used.
A second embodiment of the invention could include vendor extensions for faster CGI access, for example Oracle's Web Request BrQker, or non-CGI programmic server extensions such as Microsoft's Internet Server API (ISAPI), the Netscape API (NSAPI) or Microsoft's Active Server Pages (ASP).
In a third embodiment of the present invention, the CGI application may be replaced as a means to pass data by employing a non CGI programmic object oriented communications protocol, such as Java Servlet API, in an application performing the table look-up of the (“IS”) executed on the Application Server, and have the Java Servlet API communicate data to a Java-enabled Database Server and a Java enabled browser. Such an embodiment would avoid the slowness of passing data through stdin and stdout, OR QUERY_STRING environment variables as is done by the CGI application, thereby speeding up the data transfer process by allowing the application performing the table look-up on the Application Server to run continuously instead of stopping and starting on demand as a CGI application would do, and permitting the server's memory to cache data. The Java Servlet API also permits the servers and client to establish end to end (browser to Application Server to Database Server and back) channel security through Secure Sockets Layer (SSL) or Secure HyperText Transport Protocol (S-HTTP). It would also encrypt all data passing from the client to the Application Server and from the Application Server to the Database Server.
A fourth embodiment of the invention would use a non CGI programmic object oriented communications protocol employing embedded applications, such as Sun Microsystem's Java applets or Microsoft's Active X, containing authentication arguments and query arguments for all the selected databases connected to the document. These embedded applications can be encrypted. For example, the applets would be downloaded from the Application Server 207 to the browser 204 , which would permit the browser 204 to independently gain access to the various databases and Data Warehouses without continuously using the resources of the Application Server 207 . Presently this is not possible with Java applets since there is a restriction for security reasons on the functionality of the applet. Presently, applets can only communicate to the server from where they were received, which in this case would be the Application Server 207 . Applets cannot presently connect to other servers. Also, applets cannot inspect or change files on the local hard drive or spawn other programs, including other applets. However, these limitations are expected to be lifted once certificate based public-key cryptographic systems and digital signature based systems are perfected.
The fourth method and its corresponding apparatus operate as follows. A browser sends a request (which is in the form of a request header), corresponding to at least one link in a file of information on the Document Server to the Application Server. The Application Server, in response to receiving the request, executes an application and sends at least one embedded application, preferably encrypted, to the browser. In one embodiment, the embedded application is Sun Microsystem's Java applet. In a second embodiment, the embedded application is Microsoft's Active X. The encrypted embedded application is executed on the browser and couples an authentication argument and a query argument with the request header. Thereafter, the browser sends the request header, the query argument and the authentication argument to the Database Server. It is to be noted that the authentication argument need only be coupled to the request header and sent to the Database Server if the Database Server requires authentication for providing access to files in the database or Data Warehouse. The browser also causes the database or Data Warehouse to search for records that satisfy the query argument. Simultaneously, the embedded application that is executed on the browser causes the browser to subdivide its display window into four frames or inline frames, or fixed or pop-up windows, or any combination thereof Furthermore, the embedded application that is executed on the browser displays at least one record that satisfies the query argument in the largest of the four frames or inline frames, or fixed or pop-up windows, or any combination thereof. The embedded application also causes a series of graphic symbols (e.g., buttons corresponding to a plurality of arguments for selecting a plurality of databases to appear in at least a second of said four frames or inline frames, or fixed or pop-up windows, or any combination thereof for enabling the user to select one of a plurality of databases. In a preferred embodiment, the embedded application that is executed on the browser, further causes the browser to subdivide its display window into a second set of frames or inline frames, or fixed or pop-up windows, or any combination thereof to replace the four frames. The embedded applications causes a list of index terms to be displayed in at least one of the frames or inline frames, or fixed or pop-up windows, or any combination thereof in the second set of frames or inline frames, or fixed or pop-up windows, or any combination thereof The index terms are for selecting the Linked Term in the file of information on the Document Server.
In one embodiment, the above method further involves determining whether a first authentication of a user is needed for sending the request to the Application Server; and authenticating the user if such authentication is required.
In a preferred embodiment, the request header includes an Argument Symbol that acts as a key in a table lookup that is implemented as a hash table, associative array or a linked list. Furthermore, the embedded application that is executed on the browser correlates in a table lookup the key with one of a plurality of expert predetermined optimum values, where each expert predetermined value includes a network address for a database or Data Warehouse, a query argument, and an authentication argument. Alternatively, the key can be used to create a pop-up or floating window display for viewing by the user. The window display presents the user with a menu of choices for further areas of research pertaining to the Linked Terms where each choice corresponds to an Argument Symbol. The user chooses one of the options presented, which will send an argument that is used as a key in a table lookup in an embedded application that is executed on the browser. The table lookup then matches the key with one of a plurality of expert-predetermined optimum values used to retrieve records from the Data Warehouse or database. Each expert predetermined optimum value includes a network address for the Database Server, a query argument, and an authentication argument. In other words, the user by selecting one of the choices causes an embedded application executing on browser 204 (shown in FIG. 4) to match a key, corresponding to the selected choice in the table lookup, with a request header comprising a purpose of the request, a network address for a database network resource to which the request header is applied, a file name for an application on the database network resource, a query argument and an authentication argument. Additionally, the selection of the choice by the user causes the embedded application executing on browser 204 to send the request header to the Database Server 211 which passes it to the Data Warehouse 230 or a database through the Database Interface 220 (all shown in FIG. 4 ).
In one embodiment, the expert predetermined optimum values and the keys are stored on the Application Server and are sent to the browser in response to a request to that effect by the browser. Once the browser receives the data, it executes the embedded application and matches one of the expert predetermined optimum values with a key in the table lookup.
In a preferred embodiment, the embedded application executing on the browser sends a request header that includes the following: a) a purpose of the request; b) a network address for a Database Server, a database or Data Warehouse to which the request header is applied; c) a file name for an application stored on the Database Server; and d) a query argument and e) an authentication argument.
The Database Server, in response to receiving the request header, the authentication argument and the query argument, authenticates the user, and passes the query argument to the Data Warehouse 230 or a database through the Database Interface 220 (all shown in FIG. 4 ). The database or Data Warehouse executes a search and returns to the browser records that satisfy the query argument. In another embodiment, a database or Data Warehouse directly receives a request, an authentication argument and a query argument, authenticates the user, executes a search and returns to the browser records that satisfy the query argument. In one embodiment, an application that is executed on the Application Server or the embedded application that is executed on the browser modifies the record that satisfies the query argument and, thereafter sends the record to the browser. The embedded application that is executed on the browser causes the record that satisfies the query argument to appear in the largest of the four frames or inline frames, or fixed or pop-up windows, or any combination thereof created on the browser's window. The embedded application executing on the browser also causes a plurality of buttons corresponding to a plurality of arguments for selecting a plurality of databases to appear in the second of the four frames or inline frames, or fixed or pop-up windows, or any combination thereof on the browser's window (i.e., the means for selecting a plurality of databases). These buttons include arguments that act as keys in the table lookup with all the keys corresponding to a Linked Term in the aforementioned file of information on the Document Server. The user by clicking on one of the buttons causes the embedded application that is executed on the browser to match the key corresponding to clicked button and causes the embedded application to generate a second request header that includes the following information: a) a purpose of the request; b) a network address for a database network resource (e.g., the Database Server 211 ) (shown in FIG. 4) to which the second request header is applied; c) a file name for an application stored on the Database Server; d) a query argument; and e) an authentication argument. Additionally, the embedded application that is executed on the browser causes an excerpt of text that includes the selected link in the file of information to appear in the third one of the four frames or inline frames, or fixed or pop-up windows, or any combination thereof on the browser's window. Finally, the embedded application executing on the browser causes information associated with the source of the file of information to appear in the fourth of the four frames or inline frames, or fixed or pop-up windows, or any combination thereof in the browser's window.
It is to be noted that the embedded applications sent to the browser depend on the type of functions that one desires to transfer from the Application Server to the browser. Thus, at one extreme, one or more embedded applications are sent to the browser to allow it to perform all the functions that would otherwise be performed by the applications on the Application Server. At the other extreme no embedded applications are sent to the browser, in which case all the functions that are performed by the applications on the Application Server in the earlier described embodiments (without the transfer of embedded applications from the Application Server to the browser), continue to be performed by the applications on the Application Server. In such an embodiment, the applications on the Application Server would perform the functions performed on the browser by the execution of the embedded application(s). It is also to be noted that the range of functions, transferred from the second network resource (i.e., the Application Server) to the browser, between the above two extremes is also covered within the scope of the present invention. Thus, in one embodiment of the present invention, some but not all of the functions that would otherwise be performed by the applications on the Application Server are served by the browser.
The second FRAME element automatically loads the contents of the first of a series of HTML files into frame 2 501 . These HTML files contain the graphic images of button bars, with each button bar linked in its BREF statement to a specific network address of a network resource, such as a Database Server, a database or a Data Warehouse. These button bars alternatively appear in frame 2 501 as “pressed” or “down”, or not pressed or “up,” every time a viewer presses a button bar. Such actions can be accomplished in HTML code, or C++, ActiveX, Java, JavaScript, Visual Basic computer programs, or other programming languages 268 , 263 (shown in FIG. 5 ).
Of course, it may be appreciated by someone familiar with the art that any graphic image, or selection process or scheme may be implemented as long as it shows the viewer what databases or Data Warehouses have been selected and which ones have not. When a viewer clicks on a button bar linked via an HTTP address to a remote database or Data Warehouse, the HTML file associated with the button bar causes the viewer's browser to make a request for a record from the specified database or Data Warehouse in the same manner as described above for the initial QUERY-STRING request, with the results of the request displayed in frame 1 500 . At the same time, the button bar that the viewer has clicked appears in frame 2 501 as depressed, with the remaining button bars appearing not pressed or up. The same process described above is repeated for the other remaining button bars, each time a viewer presses a button bar.
Simultaneously with the initial loading of content in frame 1 500 and frame 2 501 , an HTML file located on the Proxy Server, containing the logos of the corporate firm sponsoring the access to the updated information, and the firm which has arranged the access to the database, or any other pertinent corporate logo or information appears in frame 4 503 . Finally, also simultaneously with the initial loading of content in frame 1 500 , frame 2 501 , and frame 4 503 , the surrounding 15 or so words to the text which the viewer initially saw and clicked on will appear in frame 3 502 . The same Linked Terms in area 303 of FIG. 6 will be highlighted in area 504 of FIG. 8 . This frame and link provides the user when he or she clicks on the link, with a means to view the entire document, automatically scrolled to the place where the link appears from the Document Server, as was illustrated in FIG. 6 .
It is to be noted when the initial menu of results are returned to datasitepl on the Application Server or the final document that the user chose from the menu is returned to datasite.pl on the Application Server (FIG. 10; 500 and FIG. 11 ), datasitepl can strip away certain predetermined HTML tags from the document. This facility would be useful, for example, if specific banners or links to other areas of the Data Warehouse need to be disabled before it reaches the user's browser.
The arrangement of frames allows the viewer to view simultaneously the results of his or her search in frame 1 500 , determine via frame 2 501 which button was depressed and which database has been selected, observe the corporate sponsor of the service in frame 4 503 , and view the surrounding 25 to 30 words surrounding the highlighted text in frame 3 502 . By clicking on the highlighted selection in frame 3 504 , the user may return to the original full text of the document he or she was viewing and automatically scroll to the exact place in the full text document which the Linked Term occurs.
FIG. 9 illustrates a means to enlarge the viewing area of frame 1 500 . This may be accomplished through a series of small graphic buttons 601 , which when clicked, will cause a window containing only frames 1 500 , frame 2 501 and frame 4 503 , without frame 3 502 to appear, as shown in display 602 . By clicking on another button in Frame 4 603 , the viewer may cause frame 3 502 to reappear. Other buttons or graphical devices on the display window may also be used to increase and/or decrease the viewing area of any frame on the display window in a matter well known to those skilled in the art.
FIG. 10 illustrates the display screen after the user invokes the expert embedded judgment and the database or Data Warehouse returns the results. The user is presented with a menu of choices with a brief summary attached corresponding to a selection of text, audio, graphics or video files or documents from which he or she can choose. The Data Warehouse or database organizes the returned records in a menu format. The user may adjust the screen in the manners described above using the graphic buttons 601 if he or she wishes, or choose a text, audio, graphics, or video document or file from area 500 of the main screen, one such selection being 604 . The user may also return to the originating document 502 by clicking on the highlighted Linked Term 504 . The user also has the option of choosing another Data Warehouse or database by clicking on any one of the buttons in frame 2 501 . Once the user makes his or her choice, the Data Warehouse or database will deliver the document corresponding to the choice in frame 1 500 .
FIG. 11 illustrates the browser's window including the “Infodex” feature of the preferred embodiment of the present invention. An “Infodex” button may be situated either in frame 2 700 , or in some other suitable area of the GUI. A second button may be situated on the main document itself. In the embodiment shown in FIG. 6, that button 304 is located just under the masthead of the newsletter. By pressing the Infodex button, a viewer activates a link to the Application Server and makes a request through his or her browser for an HTML document containing two equal frames.
FIG. 12 is a flowchart of the method of operating the “Infodex” indexing process of the present invention. At step 750 in FIG. 12, the user chooses the Infodex button. By clicking on the button, the user passes an argument by the QUERY_STRING HTTP protocol to the CGI application, infodexpl on the Application Server. At step 751 , the Application Server executes the CGI application infodexpl. As a result, at step 752 an HTML document containing an index of all the Linked Terms and their associated Data Warehouses or databases appearing in the originating HTML document is dynamically created. Simultaneously, at step 755 , infodex.pl, more specifically, the “frames” subroutine therein, creates two frames, FRAME 1 757 and FRAME 2 756 in the browser's window. At 754 , infodexpl then sends the dynamically created index file to FRAME 1 757 .
Simultaneously, at 753 , infodex.pl sends a static HTML file that explains how to use Infodex or other such useful information to FRAME 2 756 . As indicated in block 758 , the user can click on a link in the index (in FRAME 1 757 ) and send a request header to infodex.pl on the Application Server, which then sends a request header to the Document Server. The Document Server then sends the originating document, scrolled to the exact place of the Linked Term to the Proxy Server, or even directly to the browser, if that is desired. If the Document Server sends the file to infodex.pl on the Application Server, infodex.pl will forward the file to the browser and insert it in frame 2. At this point, the user can initiate the process illustrated in FIG. 5 by clicking on the highlighted Linked Term.
FIG. 13 shows the browser's window as a result of operating the “Infodex” feature. As a result, left frame 803 is shown after it is automatically loaded with a dynamically created HTML document 800 in HTML created by Java, JavaScript, C++, Visual Basic or ActiveX, or any combination thereof, or any other relevant computer programming language. In document 800 the Linked Terms of the main document are presented in an expandable file tree index 805 . By clicking on any one of the words, phrases, sentences or paragraphs with a symbol next to it, or on the “Expand” key 801 at the bottom of left frame 803 , a branch of the tree expands below the “parent” limb, revealing on the “child” limb the names of all the Data Warehouses or databases linked to the Linked Terms represented by the “parent” limb.
At the same time, right frame 804 loads an HTML document 802 which explains how to use Infodex or other such useful information. Both the right and the left frames are scrollable in either an up and down direction or in a side to side direction.
FIG. 14 shows the browser's window including “parent” limb 900 and “child” limb 901 in left frame 803 . The viewer may then click the “child” limb 901 in the left frame 803 , which causes the viewer's browser to request and load the full multimedia document in the right frame 804 and scroll to the area of the document that contains the Linked Term to the selection in left frame 803 .
FIG. 15 shows right frame 804 loaded with a document 1000 including Linked Term 1001 which is related to the “parent” whose “child” 901 the viewer clicked on. As shown in FIG. 15, the viewer will be able to see simultaneously, in left frame 803 , an index of all the Linked Terms linked to a remote database or Data Warehouse, and in the right frame 804 , the full text of the document 1000 scrolled to the Linked Term and its surrounding text. If the viewer chooses, he or she may scroll from the beginning to the end of the entire document 1000 in right frame 804 . This document is the same document discussed above and illustrated in FIG. 6, and referenced as document 301 . Accordingly, the viewer may click on the Linked Term in document 1000 and activate the same process discussed above and illustrated in FIGS. 4 to 10 above.
Thus, a cost-effective, highly efficient method and apparatus for automatically and continuously updating on demand an HTML document situated on a network resource has been described. Moreover, the method and apparatus has the additional advantages of causing the automatic updating of any document containing a Linked Term with information (current or archived) to expand and add depth and context to any document.
For example, it permits:
Departments within corporations to update critical internal documents, such as 401K plan information, for their employees without labor intensive efforts;
The information services department of corporations to distribute updated information on software used by employees by first describing the software in a text document, and then using the invention to link to any network resource which holds documents pertaining to the update.
A corporation to have its sales force make personal sales calls, distribute print documents at the time of the sales call, and then update those distributed documents over a network, such as the Internet.
Automatic updating of print documents handed out at seminars and conferences.
Physicians to place descriptions of treatments for particular patients suffering from illnesses in password protected areas of a web site, and then have the information on the latest advances of drugs, or the legal status of FDA approval of drug updated regularly.
While the present invention has been particularly described with respect to the illustrated embodiment, it will be appreciated that various alterations, modifications and adaptations may be made based on the present disclosure, and are intended to be within the scope of the present invention. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment(s), it is to be understood that the present invention is not limited to the disclosed embodiment(s) but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
For example, other gateway applications besides CGI, such as Sun Microsystem Incorporated's Java; Microsoft's Internet Server API (ISAPI) and Netscape's API (NSAPI), Java, Java applets, and Oracle's Web Request, may be used for transmission of data between the Application Server any other HTTP server. Also, immediately following the Linked Terms, graphic symbols for audio, video and text may be added to indicate to the reader the properties of the content to which the user gained access. Moreover, once the user accesses the database or Data Warehouse and views the information he or she sought, a window could appear which would allow the user to further refine the search by entering additional search terms and running another search in the database or Data Warehouse. Other embodiments would also include substituting stdin and stdout as a means to pass data through CGI to the Database HTTP Server instead of QUERY_STRING or PATH_INFO environment variables, or using Java, Java applets, Javascript or enhanced CGI as detailed above.
A fifth embodiment of the present invention uses a non-CGI programmic object oriented communications protocol employing embedded applications, such as Sun Microsystem's Java applets or Microsoft's Active X combined and coordinated with a scripted language such as Java Script or VBScript. The scripted language would contain, among other things, the authentication arguments; query arguments for all the selected databases connected to the document; the screen positions for all the windows and frames; and controls for the windows and frames. Both the embedded applications and the scripted language can be encrypted. For example, the applets and the scripted language would be downloaded from the Application Server 207 to the browser 204 , which would permit the browser 204 to independently gain access to the various databases and Data Warehouses 230 without continuously using the resources of the Application Server 207 . By carefully coordinating the applets with the scripted language, it is possible to have the applet communicate directly with a different server from which it was received, in this case a server different than the Application Server 207 , without invoking various restrictions presently placed upon the functionality of the applet when it communicates with a server other than the server from which it came.
The fifth embodiment of the present invention operates as follows. A browser 204 sends a request corresponding to at least one link in a file of information on the Document Server 202 to the Application Server 207 . Alternatively, the file of information on the Document Server 202 could have at least one link to a duplicate file of information on the Application Server 207 . In this case, the user clicks on a link in the file of information on the Document Server 202 , and views a file of information on the Application Server 207 that is a duplicate of the file of information on the Document Server 202 . The browser 204 then sends a request corresponding to at least one link in a file of information on the Document Server 202 or at least one link of information in a duplicate file of information on the Application Server 207 , as the case may be. The Application Server 207 , in response to receiving the request, executes an application and sends at least one embedded application, preferably encrypted, to the browser 204 . In one embodiment, the embedded application is Sun Microsystem's Java applet. In a second embodiment, the embedded application is Microsoft's Active X. The embedded application can be sent in combination with a scripted language such as JavaScript or VBScript, also which may be encrypted.
The embedded application can be stored on the Application Server 207 as a class file, or in compressed form as a jar and .cab file, or any compressed file that a browser 204 can download, read and execute. Additional functionality, such as the establishment, control and management of pop-up windows, frames, dynamic framesets and layers and additional button controls in the pop-up windows could added by routines written in scripted languages such as JavaScript and VBScript.
FIG. 16, shows the resulting view in the browser 204 as a consequence of the Application Server's response to the browser's request. The embedded application will permit flexibility in the arrangement of the appearance of the browser's screen 1000 , and could arrange objects (such as a button, screen or animation) in a column or row, or the size and position of each object relative to the screen can be specified. The applet's background can be colored or a bitmap can be used, and the bitmap background can be scaled to fit the applet, or it can be centered or tiled. Each object generated by the applet can be assigned a URL to link to when clicked, and a targeted frame within which to present the content.
The object may have multiple links and multiple target frames that would permit the change in the contents of two or more frames simultaneously with one click of the object. An object, such as a button, can be programmed within the applet to behave as a “Check Box” (each time a button is clicked, it stays depressed with all the other clicked buttons); a “Push Button” (each time a button is clicked, it depresses and then springs up again, and has no effect on any other button); or a “Radio Button” (each time a button is clicked, it depresses and causes any other depressed button to spring to the up position). These behaviors can exist exclusive of one another or be intermixed.
All the objects will have at least three “states”—Up, Down and Mouse-Over—which can be invoked by the applet itself or by a scripted language, such as JavaScript, at any time. A button is in the “Up” state if it is not depressed. A button is in the “Down” state if it is depressed. A button in the “Mouse-Over” state causes an action when the cursor is passed over it. Different colors, bitmaps, sounds and text labels can be assigned to each one of the states. Thus, for example, if an object is a button, a button in its “Up” state can be the color blue and emit no sound; a button in the “Mouse-Over” state can be green and emit a “swoosh” sound when the cursor is passed over it, and a button in its “Down” or depressed state can be red and emit a “click” sound when pressed. Different text styles can be reproduced on the objects, including but not limited to: Bold, Italic, Underlined, Raised and Recessed text. Text on the objects can be aligned to the left, center or right of the object, or it can be offset, and more than one line of text can be included on the object.
Bitmaps can be in GIF or JPEG formats, or any other suitable graphic format, and can be aligned to the left, right or center of the object, or they can be scaled to fit the object. Transparent GIF's can be used to create non-rectangular objects, and looped and non-looped animations may be created on the objects and may be started and restarted when the object changes its state. Objects which are animated by the applet may be moved to an X Y coordinate of the computer screen, and the applet can specify the number of frames in the animation and the number of milliseconds to wait after each frame. The applet may also resize the object to a new width and height or transform the object to a new position and size. This functionality permits screens of text to slide over one another.
Sounds associated with the objects may be in AU or WAV format, or any other suitable sound format supported by applets, and sounds may be assigned for each of the object's states. The objects may be transparent, flat, or beveled up or down, and beveled objects can be of any depth, with heavy, medium or light shading. Objects generated by the applet may have a border of any thickness or color, and border settings may be different for the object's different states.
Actions performed by an object (such as a button) can be assigned to various events which occur when interacting with the objects, such as entering the object, leaving the object or upon pressing the object. For example, these actions include, but are not limited to showing and hiding buttons, setting the state (Up, Down or Mouse-Over) of a button, and calling a JavaScript or VBScript function. Multiple actions can be assigned to a single event.
The applet's methods to hide and show an object, change the state of an object and move and resize an object may be controlled by JavaScript or VBScript routines. Conversely, the applet may also call JavaScript and VBScript routines. With respect to JavaScript, the applet may call a JavaScript routine in the form of “javascript:functioname(a,b)” or “functionname(a,b).” The applet may also call a JavaScript or VBScript routine by a URL.
The encrypted embedded application and scripted language are executed in the browser 204 and, among other things: (1) correlate in a table lookup, hash table, associative array or linked list, a key sent by the applet with one of a plurality of expert predetermined values (each expert predetermined value comprising the network address for a database or Data Warehouse 230 , a query argument, and an authentication argument); and (2) generate a second request where the request comprises a purpose of the request, a network address for a third network resource to which the request is applied, a file name for an application that is stored and executed on the third network resource, an authentication argument and a query argument, and, if required, modifies a record that satisfies the query argument. Additionally, the embedded application and scripted language preferably couple at least one authentication argument to the query argument and the request. Therefore, the embedded application and scripted language effectively couple a query argument to a request in the browser 204 on client 203 (FIG. 4 ).
FIG. 17 shows the applet ( 1001 ) with at least one additional window, after the central viewing window ( 1002 ) is slid to the lower right-hand corner of the browser's screen. This additional window could be a pop-up window, inline frame, dynamic frameset or layer. The embedded application and the scripted language in the browser 204 on client 203 preferably cause the browser 204 to pop up a central viewing window 1002 (smaller than the screen size of the browser) in front of the area of the screen reserved for the applet, which window is initially fixed at a specified X, Y coordinate in the browser window, and which permits a column and row of buttons generated by the applet to be seen at any side of the window Passing a cursor over any of the buttons to the left causes a selection of text from the file of information on the Document Server 202 , or the duplicate file of information on the Application Server 207 surrounding the Linked Term to appear in the central viewing window 1003 . The window is a semi-modal window, controlled and managed either by the embedded application or the scripted language, or by both. Semi-modal means that it has some characteristics of a modal window (it does not close automatically if one clicks in its background as typical pop-up windows do); yet unlike a modal window, it does not prevent activity in the background from taking place. For example, making a modal window appear in front of an applet would cause any buttons generated by the applet and appearing to the side of the window to freeze until the modal window is closed. In contrast, the semi-modal window permits buttons to be pressed in its background without causing it to close. A simple version of a semi-modal window uses two files and looks like the following:
FILE_ONE.html
<!DOCTYPE HTML PUBLIC “-//W3C//DTD HTML 4.0 Transitional//EN”>
<html>
<head>
<title>Intellidoc Screen</title>
<script type=“text/javascript” language=“JavaScript1.2”>
function pop-up(URL, Name, Features) {
var newWin=open(URL, Name, Features);
if (newWin.opener==null)
newWin.opener=window;
return newWin;
}
function launchNewWin( ) {
mywindow=pop-up(“FILE_TWO.html”, “”,“height=484,width=645”);
OnBlur-myWindow.focus( );
}
launcbNewWin( )
</script>
</head>
<body>
</body>
</html>
FILE_TWO.html
<HTML>
<HEAD>
<TITLE>Intellidoc Demonstration</TITLE>
<script type=“text/javascript” language=“JavaScript1.2”>
</script>
</HEAD>
<BODY BGCOLOR=“Black” onBlur=“window.focus( )”>
<em><font face=“Garamond” size=“+5” color=“Blue”>Intellidoc</font></em>
</BODY>
</HTML>
FIG. 18 shows the browser screen after a database or Data Warehouse 230 is selected. The embedded application and the scripted language, together or separately as the case may be, cause a series of buttons to appear on at least one side of the viewing window for enabling a user to manually select at least one of a plurality of databases or Data Warehouses when at least one of the buttons are depressed 1004 ; cause information associated with the source of the file (i.e., the name of the company that published the document containing the Linked Term) to appear on a side of the viewing window 1005 ; cause a sliding indicator (such as an arrow) to appear next to the database selected 1006 ; and cause a button on the indicator 1007 to request the specific text associated with the database from the Document Server 202 or Application Server 207 , as the case may be, so that the user can switch back and forth between the selected text (FIG. 17, 1003 ) and the database or Data Warehouse connected with the text 1004 . Additionally, if the user clicks on a selection of text from the file of information on the Document Server 202 , or the duplicate file of information on the Application Server 207 , all buttons linked to the text will appear in their “Down” state (as if the user had pressed them) and all other buttons will appear in their “Up” state.
In another embodiment of the present invention, at least a second series of buttons will appear along the sides of the viewing window 1008 . These buttons, when activated, will organize the buttons associated with the plurality of databases or Data Warehouses under different categories. Thus, if the user chooses the button “Markets” in the upper left hand corner, the buttons “Residential,” Brand ” and “Location” will appear at 1008 . If the user then clicks on the button “Residential,” all the database buttons connected to the term “Residential” will appear at 1004 . The user can then choose the databases he or she wants to search. Additionally, if the user clicks on a selection of text from the file of information on the Document Server 202 , or the duplicate file of information on the Application Server 207 , all buttons linked to the text will appear in their “Down” state (as if the user had pressed them) and all other buttons will appear in their “Up” state.
When the user manually selects one of a plurality of databases or Data Warehouses, the embedded application and the scripted language, together or separately correlate in a table lookup, a key, sent by the applet when the user manually selected the database or Data Warehouse 230 , with one of a plurality of expert predetermined values. Additionally, the embedded application and the scripted language, together or separately, executing on the browser 204 send a request to a third network source, such as the Database Server 211 , that include the following: (a) a purpose of the request; (b) a network address for a Database Server 211 , a database or Data Warehouse to which the request is applied; (c) a file name for an application stored on the Database Server 211 ; (d) a query argument and (e) an authentication argument. The embedded application and the scripted language, together or separately, may also modify a record that satisfies the query.
It is to be noted that the authentication argument need only be coupled to the request and sent to the Database Server 211 if the Database Server 211 requires authentication for providing access to files in the database or Data Warehouse 230 . In one embodiment, the user can also invoke the above method by clicking on the highlighted text from the file of information on the Document Server 202 or the Application Server 207 , as the case may be, in the main viewer window. In a preferred embodiment, either the embedded application or the scripted language, or both together, that is executed on the browser, further causes a pop-up window to appear under the main viewing window.
FIG. 19 shows the browser window after the user drags the viewing window to the lower right-hand side. The user may click on the title bar of the main viewer window and drags it to the side to view the pop-up window underneath 1009 . The embedded application and scripted language could cause a list of index terms to be displayed in the pop-up window. The index terms are for selecting the Linked Terms in the file of information on the Document Server 202 or the Application Server 207 .
It is to be further noted that the embedded applications and scripting languages sent to the browser 204 depend on the type of functions that one desires to transfer from the Application Server 207 to the browser 204 . Thus, at one extreme, only one or more scripted language routines and no embedded applications are sent to the browser 204 to allow it to perform all the functions that would otherwise be performed by the applications on the Application Server 207 , in which case all the functions that are performed by the applications on the Application Server 207 in the earlier described embodiments (without transfer of the embedded applications from the Application Server to the browser), continue to be performed by the scripted language. In such an embodiment, the scripted language would perform the functions performed on the browser by the execution of embedded applications. The scripted language routines may be encrypted.
At the other extreme, only embedded applications and no scripted language routines are sent to the browser 204 , in which case all the functions that are performed by the applications on the Application Server 207 in the earlier described embodiments (without transfer of the scripted language routines from the Application Server to the browser), continue to be performed by the embedded applications. In such an embodiment, the embedded applications would perform the functions performed on the browser 204 by the execution of embedded applications. It is also to be noted that the range of functions transferred from the second network source (i.e., the Application Server) to the browser 204 , between the above two extremes is also covered within the scope of the present invention.
The foregoing detailed description of the invention is provided for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise embodiment disclosed. Although the preferred embodiments of the present invention have been illustrated and described, various modifications thereof will become apparent to those skilled in the art; and, accordingly, the scope of the present invention should be defined by the claims appended hereto.
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An apparatus and corresponding method for selecting multimedia information, such as video, audio, graphics and text residing on a plurality of Data Warehouses, relational database management systems (RDMS) or object-oriented database systems (ODBA) connected to the Internet or other network, and for linking the multimedia information across the Internet, or other network, to any phrase, work, sentence and paragraph of text; or numbers; or maps; charta, and tables; or still pictures and/or graphics' or moving pictures and/or graphics; or audio elements contained in documents on an Internet or intranet web site so that any viewer of a web site, or other network resource, can directly access updated information in the Data Warehouse or a database in real time are disclosed. The apparatus and corresponding method each: (i) stores a plurality of predetermined authentication procedures (such as user names and passwords) to gain admittance to Data Warehouses or databases, (ii) stores the Universal Resource Locators of intranet and Internet addresses of a plurality of expert-predetermined optimum databases or Data Warehouses containing text, audio, video and graphic information, or multimedia information relating to the information on the web site or other network resource; (iii) stores a plurality of expert-predetermined optimum queries for use in the search engines of each of the pre-selected databases, each query representing a discrete searchable concept as expressed by a work, phrase, sentence or paragraph of text, or any other media such as audio and video on a web site, or other network resource; and (iv) presents to the user the results of a search of the Data Warehouse or database through a graphical user interface (GUI) which coordinates and correlates viewer selection criteria with the expert optimum remote database selection and queries.
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BACKGROUND OF THE INVENTION
This invention relates to a diaphragm control device for a camera, and more specifically to a diaphragm control device using a stepping motor.
With the automation of the exposure control of cameras, cameras have recently been provided with diaphragm control devices. A diaphragm mechanism of a camera has a plurality of diaphragm leaves interlocking with one another to vary the size of a diaphragm opening. A linking pin is attached at right angles to one of these diaphragm leaves, and the diaphragm opening is changed in size by turning the linking pin around the optical axis of the camera. Conventionally, there has been proposed a diaphragm control device to control the angle of rotation of the linking pin of the diaphragm mechanism by using a stepping motor. In such device, a clock pulse corresponding to the brightness of a subject is supplied to the stepping motor to rotate the motor stepwise. A stopper lever is fixed on a shaft of the stepping motor. The diaphragm mechanism is so designed as to be urged in one direction to open or close the opening in response to a depression of e.g. a release button prior to a shutter operation. The size of the diaphragm opening is determined when the turn of the linking pin is prevented by the stopper lever in the middle of the urging of the diaphragm mechanism in the other direction.
After the shutter operation is finished, the diaphragm mechanism and the stepping motor must be restored to their respective reference positions. In an initial excitation state, the stepping motor has a plurality of stop positions provided by attraction and repulsion between electromagnets serving as a stator and permanent magnets arranged on a rotor. Although the diaphragm mechanism may easily be restored to its reference position by a spring, etc., the stepping motor cannot have its reference position fixed by the biasing force of a spring or the like. The reason is that the stepping motor cannot rotate stepwise against such biasing force because of its weak turning force. Accordingly, there has been proposed a system to rotate the stepping motor in the reverse direction by applying a pulse of opposite polarity thereto and to stop the rotation at the reference position by using an optical detector. With such system, however, the device cannot be reduced in size as well as in cost. Moreover, the detector will require additional power consumption. Alternatively, there is used a system in which the number of clock pulses supplied for the rotation of the stepping motor is previously stored, and the stepping motor is restored to the reference position by reversely applying pulses of such number to the stepping motor. This system, however, still requires an expensive memory device.
The object of this invention is to provide a diaphragm control device for a camera having a simple construction and capable of setting a diaphragm opening in accordance with the brightness of a subject and returning to a reference position after the performance of an operation of the camera and before the setting of the diaphragm opening for the next camera operation.
SUMMARY OF THE INVENTION
The above object may be attained by a diaphragm control device for a camera comprising a light receiving device which produces a pulse signal in accordance with the brightness of a subject, and a reset device producing a reset pulse in accordance with a shutter operation of the camera. A motor is connected to the light receiving device and reset device and includes a rotor which has a plurality of permanent magnets and a stator so arranged as to surround the rotor, the stator having a plurality of permanent magnets, the rotor having a plurality of stop positions in an initial state and, after being restored to a given stop position in response to the reset pulse, rotating within a range not overreaching the middle position between the given stop position and another stop position adjacent thereto in response to the pulse signal. A camera diaphragm is connected to the motor and has its diaphragm opening determined in accordance with the rotation of the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a diaphragm control device for a camera according to this invention;
FIG. 2 shows a stepping motor used with the diaphragm control device of FIG. 1;
FIG. 3 is a circuit diagram of the embodiment of FIG. 1;
FIGS. 4A to 4C are performance diagrams of the stepping motor shown in FIG. 3;
FIG. 5 is a circuit diagram of another embodiment of this invention; and
FIGS. 6A and 6B are performance diagrams of the stepping motor shown in FIG. 5.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of an embodiment of the invention applied to a single-lens reflex camera, mainly showing the construction of a section near a mirror box of the camera. A mirror stopper lever 10 is pivoted to one side of the mirror box (not shown) by means of a pin 12. The mirror stopper lever 10 has one end connected with a spring 14 and biased thereby in the opposite direction to an arrow A and the other end engaging one end of a mirror lift lever 16. The mirror lift lever 16 is pivotted to the one side of the mirror box by means of a pin 18. The other end of the mirror lift lever 16 has a slit 20 which is penetrated by a pin 24 protruding from one side portion of a mirror 22. In the middle of the mirror lift lever 16, there is a pin 26 protruding toward the inside of the mirror box. The mirror lift lever 16 is connected with one end of a spring 28 the other end of which is coupled to one end of a mirror charge lever 30. Thus, the mirror lift lever 16 is biased in the direction of an arrow B. The mirror charge lever 30 is pivoted to the one side of the miror box by means of a pin 32, and is normally biased in the direction of an arrow C by a spring 34. The other end of the mirror charge lever 30 engages one end of a charge stopper lever 36. The charge stopper lever 36 is pivoted to the one side of the mirror box by means of a pin 38, and is normally biased in the opposite direction to an arrow D by a spring 40. The one end of the mirror charge lever 30 is connected with one end of a spring 42 the other end of which is coupled to an actuating lever 44 located inside the mirror charge. One end of the actuating lever 44 is pivoted to the one side of the mirror box by means of the pin 32. Thus, the actuating lever 44 is biased in the direction of an arrow E by the spring 42. In the middle of the actuating lever 44, there is a projection plate 46 jutting out to the outside of the mirror box. The bias excursion of the actuating lever 44 in the direction of the arrow E reaches a position where such excursion is prevented by the engagement between the projection plate 46 and the pin 26 projected from the mirror lift lever 16.
The other end of the actuating lever 44 extends up to the front of the mirror box, and is inserted through a notch in a coupling ring 48 which is disposed around the optical axis in the front of the mirror box. Since the actuating lever 44 is biased in the direction of the arrow E, the coupling ring 48 is urged in the direction of an arrow F. A lens (not shown) is attached to the front of the coupling ring 48 by means of a mount section. In the case of the single-lens reflex camera, a diaphragm means (hereafter referred to as diaphragm mechanism) is incorporated in the lens. The diaphragm mechanism includes a plurality of diaphragm leaves disposed at right angles to the optical axis of the camera and interlocking with one another to vary the size of the diaphragm opening, and a linking pin being attached to one of these diaphragm leaves in parallel with the optical axis. The diaphragm opening may be changed in size by turning the linking pin around the optical axis. Normally, the diaphragm mechanism is so biased as to provide an open diaphragm. The tip end of such linking pin 50 of the diaphragm mechanism extends up to the forward end portion of the actuating lever 44. In this embodiment, the linking pin 50 is supposed to be biased in the opposite direction to the arrow F. When the linking pin 50 is in its maximum bias position, that is, when the diaphragm is open, the under surface of the linking pin 50 is to touch the top face of the actuating lever 44. At a portion of the coupling ring 48 opposite to the notch thereof, there is a notch section 52 having a plurality of stages (three stages in this embodiment). A stepping motor 54 and a driver 56 therefor are disposed on the opposite side of the mirror box to the side where the aforesaid levers are located. A stopper lever 58 to engage the notch section 52 is attached to the shaft of the stepping motor 54.
FIG. 2 shows the construction of the motor means which includes stepping motor 54. Here the stepping motor 54 is supposed to be a four-phase motor. A rotating disc 60 attached to a rotor is magnetized successively to N and S polarities along the circumferential direction. A plurality of four-phase pole pins are arranged in an arc around the rotating disc 60. First- and second-phase pole pins 64 and 66 are arranged correspondingly to an N-pole magnetic domain, while third- and fourth-phase pole pins 68 and 70 are arranged correspondingly to an S-pole magnetic domain. The excitation polarity of the pole pins is successively changed by the driver 56.
FIG. 3 shows a circuit diagram of the driver 56. The output terminal of a light receiving section 72 of a light receiving means, which receives optical information from a subject and produces a voltage signal corresponding to a proper stop value, is connected to one input terminal of a comparator 74 and one input terminal of a subtracter 75. The output terminal of a reference signal generator 76 is connected to the respective other input terminals of the comparator 74 and subtracter 75. An output signal from the subtracter 75 is supplied to the T-terminals of JK flip-flops 80 and 82 through a voltage-frequency (V/F) converter 78. A release switch 84 (reset means) to produce one pulse in response to a depression of a release button is connected to the R-terminals of the flip-flops 80 and 82. The Q- and Q-terminals of the flip-flop 80 are connected respectively to one input terminals of AND gates 86 and 88, and also connected respectively to first- and third-phase windings φ1 and φ3. The first- and third-phase pole pins 64 and 68 are controlled for their conduction by these first- and third-phase windings φ1 and φ3, respectively. An output signal from the comparator 74 is supplied to the other input terminal of the AND gate 86, and is also supplied to the other input terminal of the AND gate 88 through an inverter 90. The output terminals of the AND gates 86 and 88 are connected to the input terminals of a NOR gate 92 the output terminal of which is connected to the input terminal of an inverter 94 and the K-terminal of the flip-flop 82. The output terminal of the inverter 94 is connected to the J-terminal of the flip-flop 82. The Q- and Q-terminals of the flip-flop 82 are connected respectively to one input terminals of AND gates 96 and 98, and are also connected respectively to second- and fourth-phase windings φ2 and φ4. The second- and fourth-phase pole pins 66 and 70 are controlled for their conduction by these second- and fourth-phase windings φ2 and φ4, respectively. The output terminal of the comparator 74 is connected to the other input terminal of the AND gate 96, and the output terminal of the inverter 90 is connected to the other input terminal of the AND gate 98. The output terminals of the AND gates 96 and 98 are connected to the input terminals of a NOR gate 100 the output terminal of which is connected to the J-terminal of the flip-flop 80 and is also connected to the K-terminal of the flip-flop 80 through an inverter 102. Junctions between the first- and third-phase windings φ1 and φ3 and between the second- and fourth-phase windings φ2 and φ4 are connected to a power source V CC .
Now there will be described the operation of the embodiment of the above-mentioned construction. The levers mounted on the side of the mirror box of the camera are supposed to be in the position shown in FIG. 1 when a film is wound up. When the release button is depressed, the mirror stopper lever 10 is rotated in the direction of the arrow A of FIG. 1 to be released from the engagement with the mirror lift lever 16. The mirror lift lever 16 is rotated in the direction of the arrow B by the spring 28 to raise the mirror 22. Following the rise of the pin 26 of the mirror lift lever 16 which has so far prevented the bias excursion of the actuating lever 44, the actuating lever 44 is rotated in the direction of the arrow E by the spring 42. As a result, the coupling ring 48 is rotated in the direction of the arrow F, and the linking pin 50 is rotated in the direction of the arrow F by the actuating lever 44 to reduce the diaphragm opening of the diaphragm mechanism. The reduction of the diaphragm opening depends on the angle of rotation of the coupling ring 48 before the notch section 52 of the coupling ring 48 comes in contact with the stopper lever 58. Namely, the size of the diaphragm opening can be varied by changing the stage of the notch section 52 which is to be caused to engage the stopper lever 58 by the rotation of the stepping motor 54. In this embodiment, the number of the stages of the notch section 52 is three, so that the diaphragm may be shifted between three stages. The stepping motor 54 is so designed that the stopper lever 58 may engage the central one of the three stages of the notch section 52 in the initial state. The stage to engage the stopper lever 58 is changed to vary the stop by rotating the stepping motor 54 by one step according to the brightness of the subject.
Now there will be described the operation of the circuit shown in FIG. 3, as well as the action of the stepping motor 54. When the release button of the reset means is depressed, a pulse is supplied from the release switch 84 interlocking with the release button to the R-terminals of the flip-flops 80 and 82 to reset these flip-flops. A voltage signal from the light receiving section 72, which corresponds to the proper stop value corresponding to the brightness of the subject, shutter speed and film sensitivity, is compared with an output signal from the reference signal generator 76 by the comparator 74. The output signal of the comparator 74 becomes a signal to designate the rotating direction of the stepping motor 54. On the other hand, the difference between the respective output signals of the light receiving section 72 and the reference signal generator 76 is operated by the subtractor 75, a signal corresponding to the difference is V/F-converted by the V/F converter 78, and pulses of a number (at most one pulse in this embodiment) corresponding to the voltage are supplied to the T-terminals of the flip-flops 80 and 82. Here the excitation state of the stator of the stepping motor 54 is controlled by output signals from the respective Q- and Q-terminals of the flip-flops 80 and 82. The directions of the windings are so determined that the first- and third-phase pole pins 64 and 68 becomes S- and N-poles respectively when the first-phase winding φ1 is energized, that the first- and third-phase pole pins 64 and 68 become N- and S-poles respectively when the third-phase winding φ3 is energized, that the second- and fourth-phase pole pins 66 and 70 become S- and N-poles respectively when the second-phase winding φ2 is energized, and that the second- and fourth-phase pole pins 66 and 70 become N- and S-poles respectively when the fourth-phase winding φ4 is energized. Here, to energize a winding means to supply a low level signal to the winding.
Table 1 shows the shift of the output signals of the flip-flops 80 and 82. Here it is supposed that a high level signal is produced from the comparator 74.
TABLE 1______________________________________Output TimingTerminal reset 1 2 3 4 . . .______________________________________Q of F-F 80 L H H L L . . .Q of F-F 82 L L H H L . . ..sup.--Q of F-F 80 H L L H H . . ..sup.--Q of F-F 82 H H L L H . . .______________________________________
As may be seen from Table 1, the first- and second-phase windings φ1 and φ2 are energized at time of resetting, so that the excitation state of the pole pins is such that the first- and second-phase pins 64 and 66 becomes S-poles and the third- and fourth-phase pins 68 and 70 become N-poles. Accordingly, as shown in FIG. 4A, the N-pole magnetic domain of the rotating disc 60 of the stepping motor is attracted by the first- and second-phase pins 64 and 66, and the S-pole magnetic domain is attracted by the third- and fourth-phase pins 68 and 70. At the next timing, as shown in FIG. 4B, the N-pole magnetic domain is attracted by the second- and third-phase pole pins 66 and 68, and the rotating disc 60 of the stepping motor is rotated by one step for one pole pin. Thereafter, the stepping motor 54 is rotated stepwise at each timing. Naturally, when the output signal of the comparator 74 is at a low level, the shifting direction of the excitation state of the pole pins is reversed at timing 1, as shown in FIG. 4C, so that the stepping motor 54 is rotated stepwise in the reverse direction. Since at most one pulse is supplied to the T-terminals of the flip-flops 80 and 82 in this embodiment, the stepping motor 54 is rotated by only one step. At time of resetting, therefore, the stepping motor 54 is sure to be restored to the position shown in FIG. 4A. If the flip-flops 80 and 82 are reset as shown in Table 1 after the stepping motor 54 is rotated by two steps or more, the rotating disc 60 will stop at a position which corresponds to first- and second-phase pole pins of a pole pin pair adjacent to the illustrated pole pin pair, and the initial position shown in FIG. 4A will not be able to be obtained.
In this embodiment, the comparator 74 produces a high level output signal when the signal from the light receiving section 74 is higher than the output signal of the reference signal generator 72, that is, when the subject is bright. The rotating direction of the stepping motor 54 is determined so that the stopper lever 58 may engage the innermost stage of the notch section 52 when the output signal of the comparator 74 is at a high level, and that the stopper lever 58 may engage the outermost stage when the output signal is at a low level. Accordingly, when the subject is bright, the angle of rotation of the coupling ring 48 is increased before the notch section 52 engages the stopper lever 58, so that the linking pin 50 of the diaphragm mechanism is biased to an increased degree to reduce the diaphragm opening. Although the reset pulse of the flip-flops 80 and 82 is produced in response to the depression of the release button by means of the release switch 84 in the above-mentioned embodiment, such pulse may be produced in response to the rise of the mirror in the case of direct-photometry system which measures light transmitted to the film itself during the exposure.
By limiting the working range of the stepping motor, as described above, the stepping motor is allowed surely to return to the same initial position at resetting without requiring any special means. Although two pole pins are arranged in an arc around the rotating disc 60 corresponding to each magnetic domain of the rotating disc in the above embodiment, three or more pole pins may be arranged to increase the number of steps of the stepping motor.
FIG. 5 shows a circuit diagram of the drive circuit of the stepping motor 54 according to another embodiment of the invention. An output signal from a light receiving section 72 is supplied to the T-terminals of JK flip-flops 104, 106, 108 and 110 through a V/F converter 78. An output signal from a release switch 84 is supplied to the R-terminals of the flip-flops 104, 106, 108 and 110. The Q-terminal of the flip-flop 110 is connected to a first-phase winding φ1 and also to one input terminals of OR gates 112 and 114. The output terminal of the OR gate 112 is connected to the J-terminal of the flip-flop 104 and is also connected to the K-terminal of the flip-flop 104 through an inverter 120. The output terminal of the OR gate 114 is connected to the J-terminal of the flip-flop 106 and is also connected to the K-terminal of the flip-flop 106 through an inverter 122. The Q-terminal of the flip-flop 108 is connected to a second-phase winding φ2, one input terminal of a NOR gate 118 and the other input terminal of the OR gate 112. The output terminal of the NOR gate 118 is connected to the J-terminal of the flip-flop 110 and is also connected to the K-terminal of the flip-flop 110 through an inverter 126. The Q-terminal of the flip-flop 106 is connected to a third-phase winding φ3, the other input terminal of the NOR gate 118 and one input terminal of a NOR gate 116. The output terminal of the NOR gate 116 is connected to the J-terminal of the flip-flop 108 and is also connected to the K-terminal of the flip-flop 108 through an inverter 124. The Q-terminal of the flip-flop 104 is connected to a fourth-phase winding φ4 and the respective other input terminals of the OR gate 114 and the NOR gate 116. Like the case of the foregoing embodiment, the pole pins 64, 66, 68 and 70 are controlled for their conduction by the windings φ1, φ2, φ3 and φ4, respectively. Junctions between the first- and third-phase windings φ1 and φ3 and between the second- and fourth-phase windings φ2 and φ4 are connected to a power source V CC .
In this embodiment, the stepping motor 54 is supposed to rotate only in one direction. Therefore, pulses of a number corresponding to the very output signal of the light receiving section 72 are supplied to the flip-flops 104, 106, 108 and 110. Table 2 shows the shift of the output signals of the flip-flops 104, 106, 108 and 110.
TABLE 2______________________________________Output TimingTerminal reset 1 2 3 4 . . .______________________________________Q of F-F 110 L L H H H . . .Q of F-F 108 L L L L H . . ..sup.--Q of F-F 106 H L L L L . . ..sup.--Q of F-F 104 H H H L L . . .______________________________________
As may be seen from Table 2, the excitation state at time of resetting is the same as that in the first embodiment. At the next timing, however, neither of the first- and third-phase windings φ1 and φ3 is energized, but only the second-phase winding φ2 is energized, so that the stepping motor 54 is rotated by 1/2 step, as shown in FIG. 6A. At timing 2, the second- and third-phase windings φ2 and φ3 are energized to provide the same excitation state (FIG. 6B) as the state obtained at timing 1 in the first embodiment (FIG. 4B). Thereafter, N- and S-polarities appear alternately with unexcited pins therebetween at odd-numbered timings, and the pole pins bear the excitation polarities, N and S, in pairs at even-numbered timings. Namely, in this embodiment, the stepping motor is rotated by 1/2 step at each timing. When using the driver circuit of FIG. 4, resetting will be sure to restore the stepping motor 54 to the same position even if the motor is excited up to timing 3. According to this embodiment, therefore, the diaphragm opening may vary between four stages, and the notch section 52 of the coupling ring 48, as shown in FIG. 1, is so designed as to have four stages. The stopper lever 58 corresponds to the outermost stage when the stepping motor 54 is in its initial position, and the stepping motor 54 is rotated to cause the stopper lever 58 to correspond to the innermost stage when the subject is bright. Thus, the linking pin 50 of the diaphragm mechanism is biased farthest in the direction of the arrow F of FIG. 1 to reduce the diaphragm opening.
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There is provided a diaphragm control device for a camera which comprises a light receiving section to produce stop information corresponding to the brightness of a subject, a stepping motor to rotate stepwise in response to stop information from the light receiving section, and a coupling ring to operate a linking pin of a diaphragm mechanism in accordance with the rise of a mirror, whereby the manipulated variable of the linking pin of the diaphragm mechanism, i.e. the diaphragm opening, is controlled through the engagement between a stopper lever attached to the shaft of the stepping motor and a notch section formed in the coupling ring. The angle of rotation of the stepping motor is so set as not to overreach the middle angle between one of a plurality of initial stop angles of the stepping motor and another stop angle adjacent thereto.
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BACKGROUND OF THE INVENTION
The present invention relates generally to packages for fresh red meat. Particularly, this invention is directed to the packaging of food products such that the packaged product may be maintained in one condition under certain circumstances and then converted to another condition. Specifically, packages in accordance with the present invention provide for distribution of a packaged product in a low oxygen environment and for introduction of oxygen to the product surface at a supermarket or other retail outlet. Such introduction of oxygen is achieved either by permeation of oxygen through a film in contact with the product surface or through an exchange of atmospheric oxygen with a low oxygen gaseous atmosphere contained around the product.
While a wide variety of food products can be packaged in accordance with the teachings of this invention, it is particularly advantageous in connection with the packaging of fresh red meat such that the meat may be transported in a low oxygen atmosphere, that is, preferably 0.5% O 2 or less, most preferably 0.05% O 2 or less, and then caused to bloom when it reaches a supermarket by exposure to oxygen.
Historically, large sub-primal cuts of meat have been butchered and packaged in each supermarket. This, however, can be inefficient and result in certain undesirable additional costs. For example, all cuts from a large sub-primal must be sold at once. Instead it would be preferable to permit the meat to be butchered and packaged at a central facility which benefits from economies of scale and thereafter shipped to individual supermarkets such as is done, for example, with many poultry products.
In the past, the goal of central fresh red meat processing has not been achievable because most consumers prefer to buy meat which is reddened in color as a result of exposure to oxygen. However, the meat maintains its reddened color for approximately one to three days and, thereafter, turns a brown color which is undesirable to most consumers.
Therefore, if the meat was butchered and packaged in a gas permeable (hereinafter "permeable") film, as is typical at retail, at a central location and then shipped to another location for eventual sale, in all likelihood, by the time the package reached the retail outlet the meat would have undergone the transformation to the brown color and would be effectively unsalable. Conversely, if the meat was butchered and packaged at a central location in a gas-impermeable (hereinafter "impermeable") film, either under vacuum or with vacuum and a low oxygen gas flush, and then shipped to another location for eventual sale, the meat would reach the retail outlet having a purple color which is typical of meat prior to exposure to oxygen. Heretofore, marketing efforts to teach the consumer about the harmlessness of the purple color have proved to be difficult. And, if the gas impermeable film was a component of a conventional package having a tray which is overwrapped or lidded with a film and which contains a low oxygen atmosphere, the impermeable film would have to be removed and replaced with a permeable film in order to allow for bloom of the meat to a bright red color prior to display for the consumer, negating to a large extent the benefits of a central processing facility.
A variety of packages have been developed in an effort to provide a means for transporting meat in a low oxygen environment and for quickly and easily introducing oxygen to the meat at the retail outlet immediately prior to display to the consumer.
One approach to solving this problem has involved the development of peelable films. That is, films have been developed which readily delaminate into permeable and impermeable portions. Such a film is sealed to a support member, such as a tray, which contains the meat product, thereby forming a gas impermeable package for distribution. At the retail outlet, the gas impermeable portions are peeled from the film leaving a permeable film sealed to the tray and, therefore, a gas permeable package which allows the meat to bloom to bright red because of the exchange with atmospheric oxygen.
The peelable film may extend over the contained product and be sealed to the periphery of the tray as a lid or it may be heated and draped over the product under vacuum to form to a vacuum skin package. However, for both types of packages the principal drawback is the relatively low gas transmission rate of the permeable film portion after removal of the impermeable portion. That is, although the permeable portion of the peelable film has a much higher gas transmission rate than that of the entire film prior to delamination, 5,000 to 25,000 cc/m 2 /24 hrs./atm. at 73° F. as compared to 0 to 50 cc/m 2 /24 hrs./atm. at 73° F. prior to delamination, it is still too low to effect bloom of the packaged meat in a low oxygen gaseous atmosphere in a short period of time, except in areas of intimate permeable film to meat contact.
Most of the other approaches to achieving the goal of central fresh red meat processing have involved the development of a variety of dual web packages of the type having a permeable film covering the meat product and an impermeable film, which is removed at the retail outlet, covering the permeable film wherein the permeable film and the impermeable film are separate, discreet films.
Examples of these types of packages include dual overwrap packages wherein a permeable film is wrapped around the meat and its support member and an impermeable film is wrapped about the permeable film; dual lid packages which include a permeable lid and an impermeable lid sealed to the periphery of the support member; and packages with a head space which allows for the introduction of a treating gas, typically nitrogen, carbon dioxide or some mixture of the two, between a permeable film adjacent to the meat product and an impermeable upper web. But, as is the case with the peelable films discussed above, each of these dual web packages are limited in their effectiveness by the permeability of the permeable film. Typical gas transmission rates for commercially viable gas permeable films are 5,000 to 25,000 cc/m 2 /24 hrs./atm. at 73° F. which is too low to effect rapid red meat bloom by exchange of the low oxygen gases out and the atmospheric oxygen in.
A further package developed to allow for central fresh red meat processing includes a gas impermeable upper lid with a valve defined in the lid. The package may include a treating gas between the packaged meat and the upper lid during distribution which is withdrawn through the valve and replaced with an oxygen-rich gas. Although a rapid bloom is possible with this system, it has the disadvantages of requiring trained operators at the retail outlet and relatively expensive equipment to exchange each package thus negating the cost savings of a central processing facility. The presence of the valve has the further disadvantage of creating a package appearance which is different from that which consumers are accustomed to seeing for meat packaging. Further, a gas space between the meat product and the impermeable film is required to maintain a bloomed color which yields an underfilled package appearance.
Yet another package developed to allow for central fresh red meat processing provides for an excellent exchange of gases and rapid introduction of oxygen in which an upper impermeable web covers a lower permeable web which includes unsealed areas in the seal of the permeable web to the tray. However, the intermittent sealed and nonsealed areas are formed by an altered sealing head which comprises a series of sealing "fingers" rather than a conventional, continuous sealing surface.
Thus, it is an object of the present invention to provide a package which allows for central processing of fresh red meat with minimal processing required at retail.
It is yet another object of the present invention to provide a package which is similar in appearance to that which consumers are accustomed to seeing for meat packaging.
It is a further object of the present invention to provide a package which allows for rapid bloom of fresh red meat.
It is yet another object of the present invention to provide a package which may be assembled, filled and sealed at a central processing facility on conventional equipment.
SUMMARY OF THE INVENTION
These as well as other objects are achieved by providing a package for a product which includes a product, a support member having a cavity for receiving the product and a peripheral flange, a permeable film sealed to the support member at a sealed area about the circumference of the flange for enclosing the product, a discontinuity in the sealed area between the permeable film and the flange of the support member, the discontinuity formed by a substance present between the permeable film and the flange at the sealed area, and an impermeable film enclosing the permeable film and the discontinuity.
Such objects are further achieved by providing a package for a product which includes a product, a support member having a cavity for receiving the product and a peripheral flange, a permeable gasket sealed to the flange about the circumference thereof, a permeable film sealed to the permeable gasket, thereby enclosing the product, and an impermeable film enclosing the permeable film and the gasket.
Such objects are also achieved by providing a package for a product which includes a product, a support member having a cavity for receiving the product and a peripheral flange, a permeable film sealed to the support member at the flange for enclosing the product, at least one channel defined by the permeable film and the support member, the channel being defined by at least one depressed groove in the flange thereby creating an unsealed area, the unsealed area being enclosed by the impermeable film whereby removal of the impermeable film allows for a free flow of gases through the at least one channel, into and out of said package, and an impermeable film enclosing the permeable film and the at least one channel.
These and other objects are achieved by providing a package for a product which includes a product, a support member having a cavity for receiving the product and a peripheral flange, an impermeable film sealed to the support member at a sealed area about the circumference of said flange for enclosing the product, and a discontinuity in the sealed area between the impermeable film and the flange of the support member, the discontinuity formed by a substance present between the permeable film and the flange at the sealed area.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of preferred embodiments of the invention follows, with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a package, according to the invention;
FIG. 2 is an enlarged sectional view of a flange of a package, according to the invention, showing the seals of the permeable film and channels defined within the flange;
FIG. 3 is a cross-section of the package of FIG. 1, showing the seals of the permeable and impermeable films;
FIG. 4 is a perspective view of a package, according to the invention;
FIG. 5 is an enlarged sectional view of the flange of the package of FIG. 4 after removal of the impermeable film;
FIG. 6 is a perspective view of a package, according to the invention;
FIG. 7 is an enlarged sectional view of the flange of the package of FIG. 6 during one possible mode of operation;
FIG. 8 is an enlarged sectional view of a flange of a package, according to the invention, showing a gasket sealed to the permeable film and to the flange after removal of the impermeable film; and
FIG. 9 is a cross-section of the package of FIG. 8 with the impermeable film sealed to the flange.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a package for products, particularly fresh red meat products, having a tray, an inner non-barrier or permeable film sealed to the flange of the tray, and an outer barrier or impermeable film sealed to the flange of the tray, wherein unsealed areas between the permeable film and the tray provide for a rapid introduction of oxygen into the tray cavity upon removal of the outer impermeable film. The unsealed areas may either provide open channels into the tray cavity, or may contain foreign objects which, upon removal of the impermeable film, provide such open channels or which have an exceptionally high oxygen permeability such that an open channel is not required for rapid gas exchange.
Generally, open channels between the permeable film and the flange of the tray are formed by either ridges defined within the tray flange or a nonsealable substance applied to the flange, the sealing surface of the permeable film or both. The former is illustrated in FIG. 1 of the drawings which shows a package 10 in accordance with the present invention having a tray or support member 12 with a cavity 14 for receiving a product 16 and a peripheral upper flange 18 which includes inner flange portion 20 and outer flange portion 22 separated by depression 24. Depression 24 allows for trimming of any film sealed to the inner flange portion 20 and provides a clear delineation between the sealing area for an inner permeable film and an outer impermeable film.
In the present embodiment, inner flange portion 20 includes grooves 21 defined therein and spaced about the perimeter of the flange. A top impermeable film 26 is sealed to the support member at outer flange portion 22. Preferably, a peelable seal is formed between the impermeable film 26 and outer flange portion 22 such that the outer impermeable film may be readily removed from the package at retail.
FIG. 2 is an enlarged sectional view of the flange 18 of package 10 after removal of impermeable film 26. Permeable film 28 is sealed to the support member at inner flange portion 20. However, grooves 21 defined in inner flange portion 20 provide for open channels between the tray cavity 14 and depression 24. When impermeable film 26 is sealed to outer flange portion 22, depression 24 is enclosed, as is shown in FIG. 3. However, upon removal of film 26, depression 24 and grooves 21 define open channels into tray cavity 14. Preferably, during packaging the tray cavity 14 is flushed with a low oxygen gas such as, for example, nitrogen, carbon dioxide, or, preferably, a mixture of the two. Removal of impermeable film 26 allows for a rapid release of the low oxygen gases contained within the package and for a rapid introduction of oxygen into the package thereby blooming the packaged fresh red meat product.
Open channels between the permeable film and the flange of the tray which are formed by a nonsealable substance applied to the flange, the sealing surface of the permeable film or both are represented in FIG. 4 and 5 of the drawings. FIG. 4 shows a package 30 in accordance with the present invention having a tray or support member 32 with a cavity 34 for receiving a product 36 and a flange 38 which includes inner flange portion 40 and outer flange portion 42 separated by depression 44.
In the present embodiment, nonsealed areas 43 are defined between inner flange portion 40 and permeable film 48 and are spaced about the perimeter of the flange. As can be seen from the drawing of FIG. 4, the top impermeable film 46 is sealed to the support member at outer flange portion 42. Hereagain, it is preferred that a peelable seal is formed between the impermeable film 46 and outer flange portion 42 such that the outer impermeable film may be readily removed from the package at retail.
FIG. 5 is an enlarged sectional view of the flange 38 of package 30 after removal of impermeable film 46. Permeable film 48 is sealed to the support member at inner flange portion 40 but with the nonsealed areas 43 providing open channels between the tray cavity 34 and the external atmosphere. Upon removal of impermeable film 46, nonsealed areas 43 define open channels into tray cavity 34 allowing for a release of any contained low oxygen gases and a rapid introduction of oxygen and, therefore, rapid blooming of any packaged fresh red meat product. Unlike the embodiment of FIGS. 1-3, the present embodiment does not require that the depression between the inner and outer flange portions is employed in forming the open channels between the tray cavity and the atmosphere. Thus, a single flange tray may be employed in the present embodiment so long as the impermeable film seal is formed external to the permeable film seal, either at the upper surface of the single flange or in an overwrap configuration. However, a dual flange tray such as is illustrated here has the advantage of facilitating the packaging process because the depression between the two flange portions allows for uniform trimming of the permeable film after sealing.
The nonsealed areas of package 30 of FIGS. 4 and 5 are formed by the inclusion of a nonsealable material at the sealing surface of the permeable film, the inner flange or both. Examples of nonsealable materials which may be employed in accordance with the present invention include solids such as corn starch or other powders, liquids such as olefin glycols and nonsealable gels.
The nonsealable material may be applied to the surface of the film, the flange or both or may optionally be incorporated into the surface of either structure during its manufacture. That is, both the film and the support member are comprised of one or more polymeric resins. The film may be either a monolayer or a multilayer structure. The layer which is sealed to the support member is comprised of a resin or a blend of resins which are capable of forming a seal, preferably a heat seal, with the flange of the support member. Similarly, the support member, which must be gas impermeable, is at least partially comprised of one or more polymeric resins. One preferred support member structure for use in the present invention is a barrier foamed tray comprising a foamed substrate of a resin such as polystyrene or polypropylene with a barrier sealant film laminated thereto. Non-foamed polymeric materials or pulp or paperboard may also be employed in the base tray as long as the upper surface is coated or laminated with a material which is capable of forming a seal, preferably a heat seal, with the permeable film and the impermeable film.
Sealability between the support member and the permeable and impermeable films depends on a variety of factors including melting point, softening point and crystallinity of the resins employed in the sealing layers, the type of seal to be formed and the degree of sealing desired. For example, in the seal between the support member flange and the impermeable film it is generally preferred that a peelable seal is formed in order to allow for ready removal of the impermeable film at retail. The provision of a nonsealable resin, one, for example, with a melting point and corresponding softening point too high to form heat seals at the desired sealing temperature, spaced throughout the sealing surface of one of the members to be sealed will result in nonsealed areas.
Because it is necessary to form an airtight seal between the support member outer flange portion and the impermeable film, it is generally preferred that such nonsealable resin not be included in the support member sealing surface, although it would be possible to provide a resin which is not sealable to the permeable film but is sealable to the impermeable film. Instead, it is preferred that such a nonsealable resin be incorporated into the sealing surface of the permeable film. That is, stripes of a nonsealing resin are incorporated into the sealing surface of the permeable film during its manufacture. During packaging, as a roll of the permeable film is employed to cover the product in the tray cavity and is sealed to the inner flange portion of the tray about the periphery thereof, the stripes of nonsealable resin form nonsealed areas such as are shown at FIG. 5. The impermeable film encloses the product but upon its removal the nonsealed areas provide open channels allowing for a rapid introduction of oxygen to the packaged product.
FIGS. 6 and 7 illustrate an alternative embodiment of the present invention wherein the means for forming nonsealed areas in the seal between the permeable film and the support member flange is a foreign object, here a drawstring, present at the seal which forms an open channel upon its removal. FIG. 6 shows a package 50 in accordance with the present invention having a tray or support member 52 with a cavity 54 for receiving a product 56. Unlike the trays shown for all of the other embodiments of the present invention, support member 52 has a single flange 58.
Although a dual flange tray may be employed in the present embodiment, this embodiment is especially adaptable for use with a conventional single flange tray. A drawstring 61 is provided between permeable film 68 and flange 58 and is incorporated into the seal between the two. Preferably, the drawstring is coated with a sealable substance so that it is sealed to the flange and the film, rather than being merely physically trapped within the seal. However, the drawstring may be either coated or non-coated such that it either seals well (as with a sealable resin coating), seals loosely (such as may be achieved with a wax coating), or does not seal at all to the flange and the film.
For the present embodiment there is no open channel into tray cavity 54 until one is made by removal of the drawstring at retail as is illustrated in FIG. 7. Although FIG. 7 demonstrates removal of the drawstring 61 by pulling it along the length of the sealed area between permeable film 68 and flange 58 to form an enlarged open channel, it is also within the scope of the present invention to pull the drawstring straight from the package to form smaller channels having dimensions substantially equal to the those of the drawstring itself.
Although the present embodiment may employ separate permeable and impermeable films, it is unique in that there is no need for the impermeable film to enclose an open channel or channels because there are no open channels until the package is handled at retail. Thus, the permeable and impermeable films may comprise a single film which can be delaminated into permeable and impermeable webs. Such a multilayer film is sealed to the tray flange with the permeable layer or layers adjacent to the tray and the impermeable layer or layers forming an uppermost surface. At retail the impermeable web is delaminated from the film leaving the permeable web sealed to the tray. The drawstring is then removed to form open channels into the tray cavity in order to allow for the rapid introduction of oxygen to the packaged fresh red meat. As an alternative, an impermeable film may be sealed to or laminated to a permeable film during packaging for the same end result at retail.
As with many of the other embodiments of the invention described herein, the impermeable film can be integral with and peelable from the permeable film and thus sealed at the same location on the single flange; or, the impermeable film can comprise a separate film overlying the permeable film and optionally sealed at a separate location on the flange. As a further alternative the present package may include an impermeable film only. The removal of one or more drawstrings may be employed to form open channels for sufficient gas exchange without the use of a permeable film.
If, however, a dual flange, dual film approach is employed, the drawstring may advantageously be tucked into the depression between the flange portions such that it does not extend into the seal between the outer flange portion and the impermeable film and out of the package itself during transport. Thus, possible contamination of the drawstring and, consequently, the package can be avoided.
As an alternative to a foreign object at the flange/permeable film seal which is removed in order to provide for a gas exchange at retail, FIGS. 8 and 9 show an object which is not removed but which provides for an introduction of oxygen upon removal of an upper impermeable web. FIG. 9 shows a cross-section of package 70 in accordance with the present invention having a tray or support member 72 with a cavity 74 for receiving a product and an flange 78 which includes inner flange portion 80 and outer flange portion 82 separated by depression 84.
In the present embodiment, inner flange portion 80 has sealed to the upper surface thereof a permeable gasket 81 which extends about the perimeter of the tray at that upper surface and a permeable film sealed over the gasket along the inner flange. The permeable gasket can be continuous around the entire inner flange or a segment, depending upon the oxygen permeability required for the package or other factors. A top impermeable film 86 is sealed to the support member at outer flange portion 82. Hereagain, it is preferred that a peelable seal is formed between the impermeable film 86 and outer flange portion 82 such that the outer impermeable film may be readily removed from the package at retail.
FIG. 8 is an enlarged sectional view of the flange 78 of package 70 after removal of impermeable film 86. Permeable film 88 is sealed to the gasket 81 which is sealed to inner flange portion 80. Optionally, a gasket may be applied to the flange with an adhesive and then heat sealed to the permeable film. Gasket 81 may be perforated or porous but preferably has a permeability allowing for gas diffusion into the package equivalent to a package having a permeable film having an oxygen transmission rate of greater than about 100,000 cc/m 2 /24 hr. 1 atm. 73° F. Furthermore, as an alternative, a smaller object which is porous, perforated, or has at least one channel defined therethrough may be contained between and sealed to permeable film 88 and inner flange portion 80 without being a gasket, such as the segment described above. That is, one or more of such highly transmissible objects may be contained within that seal in order to allow for a release of any contained low oxygen gases and a rapid introduction of oxygen into the tray cavity upon removal of the impermeable film. Inter alia, the term "discontinuities" as used herein therefore includes, for example, the nonsealed areas or channels described above that are formed by a nonsealable substance, a nonsealable portion of the permeable film or substrate, a foreign object, e.g. a drawstring, and/or a permeable gasket.
The permeable film or web of the present invention is an oxygen permeable or non-barrier film or skin which may be a formable or stretchable material. Typical polymeric materials for the present permeable film may include any material which may be securely sealed and bonded to the support member, such as polyethylene or any of a variety of ethylene copolymers including, for example, ethylene vinyl acetate, ethylene acrylate copolymers, ethylene acrylic acid copolymers including metal neutralized salts thereof, and ethylene alpha-olefin copolymers. Such ethylene alpha-olefins may be heterogeneous or homogeneous in nature. That is, ethylene alpha-olefins which have been formed by conventional Zeigler-Natta catalysis and are heterogeneous in nature, such as linear low density polyethylene (LLDPE), are within the scope of the present invention as well as such copolymers which are formed by single site catalysis, such as any of a variety of forms of metallocene catalyst technology, and are homogeneous in nature are also within the scope of the present invention. A preferred permeable film for use in accordance with the present invention is a symmetrical, five layer oriented film having the structure:
EVA/LLDPE/EVA/LLDPE/EVA
although a wide variety of permeable films may be employed.
The impermeable film or web of the present invention may be any suitable barrier layer, film or laminate which is substantially impermeable to gas such as oxygen so that a fresh meat product contained in a vacuum or other low oxygen atmosphere possesses an enhanced shelf life over a package without the barrier layer. Suitable polymeric materials having gas barrier properties for use in the present invention include ethylene vinyl alcohol copolymers, vinylidene chloride copolymers (PVDC) such as vinylidene chloride vinyl chloride or vinylidene chloride methyl acrylate. Laminates of a sealable film and a barrier structure which includes a barrier layer and a tough, non-forming material such as a biaxially oriented nylon or biaxially oriented polyester are especially preferred for use as the impermeable lidding of the present inventive packages. A preferred impermeable web has the structure:
biax nylon/PVDC//EVA/LLDPE/seal
wherein the double slashes (//) indicate adhesive lamination of the two webs, although a variety of laminates and multilayer films may be employed as the impermeable web of the present invention.
Generally, the films or webs which may be employed in accordance with the present invention may be monolayer or multilayer. Multilayer films may be employed when all of the properties required of the film cannot be achieved by a single polymeric component or a blend of polymers in a single layer. For example, an impermeable film to be sealed to a tray in all likelihood will comprise a multilayer film because several properties are needed including peelable sealability, oxygen barrier and impact properties, and outer abuse properties. Thus, the film employed will most likely contain three layers at a minimum: a seal layer, a barrier layer and an outer abuse layer. Further internal layers such as adhesive layers and bulk layers may also be included. Laminates of sealable films and nonforming materials such as biaxially oriented polyester or biaxially oriented nylon are also within the scope of the present invention and are widely recognized as superior lidstocks for tray-type packages.
The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents.
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A package which allows for butchering and packaging of fresh red meat at a centralized facility is provided which includes a support member such as a tray for receiving and supporting the meat, a permeable film enclosing the meat and an impermeable film enclosing the permeable film which remains in place during distribution and is removed at retail. A discontinuity in the seal between the permeable film and the tray provides for rapid introduction of oxygen to the packaged meat.
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BACKGROUND AND SUMMARY OF THE INVENTION
Vibration dampers for friction clutch assemblies have been in use for many years for the purpose of neutralizing torsional vibrations emanating from a vehicle engine which would otherwise cause disturbing noises in the transmission and driveline. The vibration damper is utilized in a conventional clutch ahead of a manually operated transmission for an automotive vehicle or may be used where a lock-up clutch is inserted in a torque converter for an automatic transmission.
A vibration damper assembly normally will include an output hub internally splined to an output shaft, a projection or flange extending radially from the hub, and a spring retaining plate and a clutch plate sandwiching the flange. The clutch plate carries the friction surfaces adjacent its outer periphery and is secured to the spring retainer plate by a plurality of rivets extending through arcuate recesses in the outer periphery of the flange. The flange and plates have aligned circumferentially spaced openings therein to receive damper springs which allow limited relative rotation between the hub and the plates. The hub is conventionally a forging and includes shoulders adjacent the flange and barrel machined to provide suitable pilots for the central openings in the plates. The present invention provides an improved vibration damper assembly.
The present invention relates to an improved vibration damper assembly utilizing a one-piece stamped clutch hub in the assembly. The clutch hub is formed with the barrel entirely on one side of the flange without the use of shoulders for pilots to position the spring retainer and clutch plates and any washers sandwiching the flange. Positioning means are formed integral with the flange to pilot the members on each side of the flange.
The present invention also comprehends a one-piece stamped clutch hub and flange for a vibration damper assembly wherein a plurality of projections are formed on each surface of the flange adjacent the barrel of the hub to pilot the plates and washers assembled with the hub and flange to form the damper assembly. A simple die operation acts to form the pilot projections simultaneously on each side of the flange and allows the use of a flat sheet stock for the clutch hub at a considerable saving in cost over other known designs.
Further objects are to provide a construction of maximum simplicity, efficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view taken from the right-hand side of FIG. 2 of a vibration damper assembly utilizing a one-piece stamped clutch hub.
FIG. 2 is a vertical cross sectional view of the vibration damper assembly taken on the irregular line 2--2 of FIG. 1.
FIG. 3 is a front elevational view of the one-piece stamped clutch hub of FIG. 1.
FIG. 4 is a vertical cross sectional view taken on the irregular line 4--4 of FIG. 3.
FIG. 5 is an enlarged partial cross sectional view of a pilot projection.
FIG. 6 is a front elevational view of an alternate embodiment of stamped clutch hub.
FIG. 7 is a vertical cross sectional view taken on the irregular line 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the disclosure in the drawings wherein are shown illustrative embodiments of the present invention, FIGS. 1 and 2 disclose a vibration damper assembly 10 for use in a clutch assembly for an automotive vehicle or in other industrial products. The assembly includes a one-piece stamped clutch hub 11, a generally circular spring retainer plate 12, a driven plate 13 and one or more annular washers and/or friction springs 14.
The spring retainer plate 12 is generally circular with a central opening 15 therethrough and has four circumferentially spaced spring pockets 16; each pocket having opposite end walls 17, 17, an outwardly and upwardly curved inner lip 18, and an outwardly and downwardly curved arcuate outer lip 19. Interposed between each pair of adjacent pockets is an opening 21 to receive a shoulder or stop pin 22 which extends between and secures the plates 12 and 13 together.
The driven plate 13 also is generally circular with a central opening 23, a plurality of spring pockets 24 of the same number and aligned with the pockets 16 in the plate 12, openings 25 to receive the shoulder or stop pins 22, and a plurality of openings 26, 26' at the periphery of the plate. Each spring pocket 24 includes opposite end walls 27, 27, an upwardly and outwardly curved inner lip 28 and a downwardly and outwardly curved outer arcuate lip 29. The openings 26' located at spaced intervals in the series of openings 26 are slotted at 31. A plurality of circumferentially spaced radially outwardly extending spring cushions 32 are riveted to the outer periphery of the disc or plate 13 by rivets 33 received in some or all of the openings 26, with the exception of the openings 26'. Additional rivets 34 may be positioned in one or more of the openings 26' to balance the assembly for use in a clutch. The cushions 32 in turn carry generally annular friction facings 35 on the opposite sides thereof adapted to be positioned between driving members in a conventional clutching manner. The facings 35 are suitably secured to the cushions 32 by rivets 36.
The one-piece clutch hub 11 is stamped from flat sheet stock, such as Republic Maxi-Form 50 sheet steel, with a barrel 37 formed entirely on one side of an integral radially outwardly extending spring-abutting flange 38; the hub having internal splines 39 for an operative connection to a driven shaft (not shown). As more clearly seen in FIGS. 3 and 4, the flange 38 is provided with four circumferentially equally spaced spring windows comprising recesses or pockets 41 opening into the periphery of the plate that are adatped to be in alignment with the spring pockets 16 and 24 of the plates 12 and 13, respectively. Interposed between each adjacent spring recess is a shallower recess 42 opening into the plate periphery and adapted to be aligned with the stop pins 22.
Adjacent the barrel of the hub 37 are formed a plurality of piloting means comprising pilot projections 43, 44, with the alternate projections extending from the opposite sides of the flange 38. As shown, there are three projections or bosses 43 extending from the left-side, as seen in FIG. 4, of the flange and three projections or bosses 44 extending from the barrel side of the flange. These projections are extruded in the flange during the stamping operations forming the hub, with the recesses 45 behind the projections 43, 44 formed as the projections are extruded. The projections are utilized to pilot the spacers and/or spring washers 14 to maintain the concentricity between the hub and washers, and the spring retainer plate 12 and the driven plate 13 may also be piloted in the same manner to preserve the concentricity thereof. However, alternatively, the openings 15 and 23 in the plates may be given a small amount of clearance relative to the projections to allow the plates to pilot themselves relative to the hub by the way of the four damper springs 46 received in the aligned spring pockets 16, 41 and 24.
To assemble the vibration damper 10, the spacers and/or spring washers 14 are piloted onto the projections 43, 44 on each side of the flange 38, the spring retainer plate 12 is positioned over the barrel 37 of the hub 11, and the damper springs 46 are positioned in the recesses 41 in the flange and the spring pockets 16 in the plate 12. The stop pins 22 are located in the recesses 42 and project into the openings 21, and the driven plate 13 is positioned on the opposite side of the flange with the spring pockets 24 receiving the springs 46 and the openings 25 receiving the other ends of the pins 22. The opposite ends of the stop pins 22 are then headed as at 47 to retain the assembly together.
In use, the assembly 10 is positioned within a conventional clutch arrangement between a fly wheel and a pressure plate and with the barrel 37 of the hub 11 operatively connected via the splines 39 with the splined end of a driven shaft. The damper springs 46 act to allow but limited relative rotation between the connected plates 12 and 13 and the barrel 37 and flange 38 when the clutch is engaged. The recesses 42 in the flange 38 cooperate with the stop pins 22 to limit the extent of arcuate movement of the plates relative to the hub. The vibration damper operates in a conventional manner as known from prior damper assemblies.
FIGS. 6 and 7 disclose an alternate embodiment of hub 51 having a barrel 52 extending entirely from one side of a flange 54 integral therewith, the barrel having a plurality of internal splines 53. The flange 54 is larger in its radial dimension than the flange 38 of the hub 11 and is provided with a plurality (shown as six in number) of spring windows 55 circumferentially spaced therein. Also, a plurality of recesses 56 are provided in equally spaced relation in the periphery of the flange. The recesses are shown as three in number and are positioned between adjacent pairs of spring windows 55.
As in the previous embodiment, three bosses or projections 57 are extruded from the barrel side of the flange 54 and three bosses 58 are extruded from the opposite side of the flange. The assembly and operation of a vibration damper utilizing this hub 51 are substantially identical to that described for the first embodiment.
While only three round projections or bosses are shown projecting from each side of the flange on the hub, obviously any convenient number of bosses and/or other shapes for the bosses may be utilized for this structure without departing from the spirit or intent of the present invention.
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A one-piece flanged clutch hub produced from flat sheet stock for utilization in a vibration damper type of driven member of a friction clutch assembly. The flanged hub is provided with a plurality of small projections formed from the flange portion on each side thereof close to the barrel of the hub to pilot other elements of the clutch assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a division of U.S. application Ser. No. 11/414,512 filed Apr. 28, 2006 (issued as U.S. Pat. No. 7,401,664 on Jul. 22, 2008). The present invention and patent application claim priority under the Patent Laws from U.S. application Ser. No. 11/414,512 filed Apr. 28, 2006 (issued as U.S. Pat. No. 7,401,664 on Jul. 22, 2008) and from U.S. application Ser. No. 11/414,514 filed Apr. 28, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to wellbore drilling top drive systems; parts thereof; multi-seals for shafts thereof; and methods of their use.
2. Description of Related Art
The prior art discloses a variety of top drive systems; for example, and not by way of limitation, the following U.S. patents present exemplary top drive systems and components thereof: U.S. Pat. Nos. 4,458,768; 4,807,890; 4,984,641; 5,433,279; 6,276,450; 4,813,493; 6,705,405; 4,800,968; 4,878,546; 4,872,577; 4,753,300; 6,007,105; 6,536,520; 6,679,333; 6,923,254—all these patents incorporated fully herein for all purposes.
Certain typical prior art top drive drilling systems have a derrick supporting a top drive which rotates tubulars, e.g., drill pipe. The top drive is supported from a travelling block beneath a crown block. A drawworks on a rig floor raises and lowers the top drive. The top drive moves on a guide track.
The prior art reveals a variety of elastomeric lip seals for sealing against rotating shafts. Such seals are frequently used to contain lubricating oil in gear boxes and other mechanical assemblies. Because of their rubbing contact with an adjacent shaft, such seals eventually wear or are damaged to the point that the lubricant or oil they are meant to contain may leak out, causing various negative consequences. Repair or replacement of such seals can entail significant time and expense, and lost production, often requiring the removal of other machine components before clear access to the seal can be obtained.
In the prior art are a variety of top drives which have a rotating main shaft and a thrust bearing apparatus which bears the weight of the top drive and of tubulars connected thereto. In order to prevent lubricant for the thrust bearing apparatus from flowing down, a shaft seal is used with a seal member that contacts the exterior surface of the rotating shaft. When these seals wear out, it is an expensive and time-consuming task to access them and replace them.
BRIEF SUMMARY OF THE INVENTION
The present invention, in certain aspects, provides a top drive with a shaft sealing assembly with at least two seals: at least one primary seal for use initially and at least one secondary seal that is movable into place when the primary seal becomes ineffective due to wear or damage.
In one particular aspect the secondary shaft seal (or seals) is carried on a movable support which is selectively movable when the primary seal becomes worn. The secondary seals can be moved into place to sealingly contact the shaft exterior without accessing the primary seals and without removal of the primary seals. Multiple sealing surfaces are provided on the shaft so that the secondary seal(s) can be moved into sealing contact with corresponding sealing surface(s).
The present invention discloses, in certain embodiments, a top drive system with a drive motor; a gear system coupled to the drive motor; a drive quill and/or main shaft coupled to the gear system; a top drive support system for supporting various items; and a multi-seal apparatus according to the present invention for sealing against a shaft, (e.g. the main shaft, a quill, and/or a lowest rotating element) with a primary seal (or seals) and secondary seal or at least one secondary seal that can be moved into a sealing relationship with a shaft of the system, e.g. the main shaft and/or the quill, when the primary seal is no longer effective. In one aspect, the secondary seal (or seals) is isolated within part of a lubricant bath or gear box or gear housing with lubricant therein so that the secondary seal (or seals) is in a lubricant bath and is protected from external debris and contaminants prior to its movement and sealing engagement with a seal surface. Thus, the secondary seal (or seals) is maintained in a virtually new, pristine condition until it is placed in use.
What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
New, useful, unique, efficient, non-obvious top drive systems, multi-seal shaft sealing assemblies for such systems, and methods of their use; and
New, useful, unique, efficient, non-obvious top drives with a shaft sealing apparatus with a first seal (or seals) and with a second seal (or seals), the second seal(s) movable into place to seal a shaft when the first seal(s) no longer seal effectively.
The present invention, in certain aspects, provides a top drive system for wellbore operations, the top drive system including: a main body; a motor apparatus (e.g. one motor, or two spaced-apart motors); a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable; a quill connected to and around the main shaft; a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft; upper components connected to the main body above the top end of the main shaft; and the main shaft removable from the top drive system by disconnecting the main shaft from the quill, by disconnecting the upper components from the main body, and by lifting the main shaft from the quill. In certain aspects such removal of the main shaft is done without any lubricant being lost from an enclosed space containing the gear system.
In one aspect, the present invention discloses a method for removing a main shaft from a top drive system, the method including: disconnecting the main shaft from a quill of the top drive system, the top drive system having a main body, a motor apparatus, a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable, a quill connected to and around the main shaft (the quill being a generally hollow cylindrical member or shaft), a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft, the main shaft passing through the gear system, upper components connected to the main body above the top end of the main shaft, the main shaft removable from the top drive system by disconnecting the main shaft from the quill, by disconnecting the upper components from the main body and moving the upper components from above the main shaft, and by lifting the main shaft from the quill; disconnecting the upper components from the main body; and lifting the main shaft from the quill. In certain aspects of the method wherein the gear system is in lubricant within an enclosed space and the main shaft is removed without loss of lubricant from the enclosed space.
Accordingly, the present invention includes features and advantages which are believed to enable it to advance technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
New, useful, unique, efficient, non-obvious top drive systems, components and parts thereof, and methods of their use;
Such systems with an effective main-shaft/quill connection;
Such systems with a removable main shaft; and
Such systems with two supporting bails.
The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or equivalent embodiments.
FIG. 1 is a schematic view of a prior art top drive drilling system.
FIG. 2A is a front view of a top drive system according to the present invention.
FIG. 2B is a side view of a top drive system according to the present invention.
FIG. 2C is a top view of the top drive system of FIG. 2A .
FIG. 2D is a rear isometric view of FIG. 2A .
FIG. 2E is a front isometric view of FIG. 2A .
FIG. 2F is a front isometric view of part of FIG. 2A .
FIG. 2G is a side view of the top drive system of FIG. 2A connected to a dolly.
FIG. 3A is a front cross-section view of the top drive system of FIG. 2A .
FIG. 3B is a cross-section view showing part of the top drive system of FIG. 3A .
FIG. 3C is a cross-section view showing part of the top drive system of FIG. 3A .
FIG. 3D is a cross-section view showing part of the top drive system of FIG. 3A .
FIG. 4 is a perspective view of part of the top drive system of FIG. 2A .
FIG. 5 is a perspective view of part of the top drive system of FIG. 2A .
FIG. 6 is a perspective view of part of the top drive system of FIG. 2A .
FIG. 7 is a schematic view of a prior art top drive drilling system.
FIG. 8 is a front view of a top drive system according to the present invention with seal apparatus according to the present invention.
FIG. 9 is a cross-section view of part of the system of FIG. 2 .
FIG. 9A is a cross-section view of part of a system according to the present invention.
FIG. 10A is a cross-section view of a system according to the present invention.
FIG. 10B is an enlargement of part of the system of FIG. 10A .
FIG. 10C is a cross-section view showing a shift in part of the system of FIG. 10A .
FIG. 10D is a cross-section view of part of a system according to the present invention.
Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a top drive system according to the present invention which is structurally supported by a derrick 11 . The system 10 has a plurality of components including: a swivel 13 , a top drive 14 according to the present invention (any disclosed herein), a main shaft 16 , a housing 17 , a drill stem 18 /drillstring 19 and a drill bit 20 . The components are collectively suspended from a traveling block 12 that allows them to move upwardly and downwardly on rails 22 connected to the derrick 11 for guiding the vertical motion of the components. Torque generated during operations with the top drive or its components (e.g. during drilling) is transmitted through a dolly to the derrick 11 . The main shaft 16 extends through the motor housing 17 and connects to the drill stem 18 . The drill stem 18 is typically threadedly connected to one end of a series of tubular members collectively referred to as the drillstring 19 . An opposite end of the drillstring 19 is threadedly connected to a drill bit 20 .
During operation, a motor apparatus 15 (shown schematically) encased within the housing 17 rotates the main shaft 16 which, in turn, rotates the drill stem 18 /drillstring 19 and the drill bit 20 . Rotation of the drill bit 20 produces an earth bore 21 . Fluid pumped into the top drive system passes through the main shaft 16 , the drill stem 18 /drillstring 19 , the drill bit 20 and enters the bottom of the earth bore 21 . Cuttings removed by the drill bit 20 are cleared from the bottom of the earth bore 21 as the pumped fluid passes out of the earth bore 21 up through an annulus formed by the outer surface of the drill bit 20 and the walls of the bore 21 .
FIGS. 2A-2G illustrate a top drive system 100 according to the present invention (which may be used as the top drive system 10 , FIG. 1 ) which has supporting bails 104 suspended from a becket 102 . Motors 120 which rotate a main shaft 160 are supported on a main body 130 . A bonnet 110 supports a gooseneck 106 and a washpipe 108 through which fluid is pumped to and through the system 100 and through a flow channel 163 through the main shaft 160 . Within the bonnet 110 are an upper packing box 115 (connected to the gooseneck 106 ) for the washpipe 108 ; and a lower packing box 117 for the washpipe 108 .
A main gear housing 140 encloses a bull gear 142 and other associated components as described in detail below.
A ring gear housing 150 encloses a ring gear 152 and associated components as described in detail below.
A drag chain system 170 encloses a drag chain 172 and associated components including hoses and cables as described below. This drag chain system 170 eliminates the need for a rotating head used in several prior systems and provides sufficient rotation for reorientation of the link adapter 180 and items connected thereto.
Bolts 112 (see FIGS. 2E and 2F ) releasably secure the bonnet 110 to the body 130 . Removal of the bolts 112 permits removal of the bonnet 110 . Bolts 164 through a load shoulder 168 releasably secure the main shaft 160 to a quill 190 (see FIG. 3A ). The quill 190 is a transfer member between the main shaft 160 and the bull gear 142 and transfers torque between the bull gear 142 and the main shaft 160 . The quill 190 also transfers the tension of a tubular or string load on the main shaft to the thrust bearings 191 (not to the bull gear 142 ). The transfer of torque between the main shaft 160 and the quill 190 is effected with a plurality of spaced apart expandable tapered screw-in torque transfer bushings 159 which, in certain aspects, reduce or eliminate play between the main shaft 160 and the quill 190 . An end 160 a of the main shaft 160 (see FIG. 2F ) is referred to as the “washpipe end.” One or more seal retainer bushings 166 (shown schematically, FIG. 2A ) are located above the load shoulder 168 . As described in detail below, removal of the bonnet 110 and bolts through the load shoulder 168 securing the main shaft 160 to a quill 190 , permits removal of the main shaft 160 from the system 100 . Upper quill bearings 144 are above a portion of the quill 190 .
As shown in FIG. 2G , the system 100 is movable on a mast or part of a derrick (like the derrick 11 and on its rails 22 ) by connection to a movable apparatus like the dolly 134 ( FIG. 2G ). Ends of links 133 are pivotably connected to arms 131 , 132 of the body 130 . The other ends of the links 133 are pivotably connected to the dolly 134 . This structure permits the top drive and associated components to be moved up and down, and toward and away from a well centerline, as shown by the structure in dotted line (toward the derrick when drill pipe is connected/disconnected while tripping; and to the well center during drilling). Known apparatuses and structures are used to move the links 133 and to move the dolly 134 .
Upper parts of the bails 104 extend over and are supported by arms 103 of the becket 102 . Each bail 104 has two spaced-apart lower ends 105 pivotably connected by pins 107 to the body 130 . Such a use of two bails distributes the support load on the main body and provides a four-point support for this load, economically reducing bending moments on the main body.
The quill 190 (see FIG. 3A ) rests on main thrust bearings 191 which support the quill 190 , the main shaft 160 , and whatever is connected to the main shaft 160 (including whatever load is borne by the main shaft 190 during operations, e.g. drilling loads and tripping loads). The body 130 houses the main thrust bearings 191 and contains lubricant for the main thrust bearings 191 . An annular passage 145 (see FIG. 3C ) provides a flow path for lubricant from the gear housing 140 to the thrust bearings.
Shafts 122 of the motors 120 drive couplings 123 rotatably mounted in the body 130 which drive pinions 124 in the main gear housing 140 . The drive pinions 124 drive a bull gear 142 which, connected to the quill 190 with connectors 192 (e.g., but not limited to, taper lock connectors in which turning bolts 193 ((see FIG. 3D )) tightens the connectors screwing together parts 194 which push the parts 194 against the quill 190 and which push out wedges 195 against the bull gear 142 securing the bull gear 142 to the quill 190 ), drives the quill 190 and thus the main shaft 160 which is connected to the quill 190 . Radial bearings 197 support the bull gear 142 .
The bull gear 142 is within a lower portion 146 of the gear housing 140 which holds lubricant for the bull gear 142 and is sealed with seal apparatus 148 so that the lubricant does not flow out and down from the gear housing 140 . Any suitable known rotary seal 148 may be used or, as in one particular aspect the seal apparatus 148 is like the seal apparatus disclosed in co-owned U.S. application Ser. No. 11/414,514 filed Apr. 28, 2006 entitled “Multi-Seal For Top Drive Shaft”, which is incorporated fully herein for all purposes. With such a seal apparatus, which has rotatable bolts 149 , when a first seal structure no longer seals effectively, the bolts 149 are rotated and a second seal structure is shifted into place to effect a good seal. Within the gear housing 140 , the bull gear 142 and the drive pinions 124 sit in lubricating oil, eliminating the need for spray nozzles, distribution pumps, and flow or pressure sensors employed in various prior systems.
The ring gear housing 150 which houses the ring gear 152 also has movably mounted therein two sector gears 154 each movable by a corresponding hydraulic cylinder apparatus 156 to lock the ring gear 152 (see, e.g., FIGS. 3B and 4 ). With the ring gear 152 unlocked (with the sector gears 154 backed off from engagement with the ring gear 152 ), items below the ring gear housing 150 (e.g. a pipe handler on the link adapter) can rotate. The ring gear 152 can be locked by the sector gears 154 to act as a backup to react torque while drill pipe connections are being made to the drillstring. The ring gear 152 is locked when a pipe handler is held without rotation (e.g. when making a connection of a drill pipe joint to a drillstring). An hydraulic motor 158 (shown schematically), via gearing 159 , turns the ring gear to, in turn, rotate the link adapter 180 and whatever is suspended from it; i.e., in certain aspects to permit the movement of a supported tubular to and from a storage area and/or to change the orientation of a suspended elevator, e.g. so that the elevator's opening throat is facing in a desired direction. Typical rig control systems are used to control the motor 158 and the apparatuses 156 and typical rig power systems provide power for them.
In a variety of prior top drive systems a rotating head with a plurality of passageways therethrough is used between some upper and lower components of the system to convey hydraulic and pneumatic power used to control system components beneath the rotating head. Such a rotating head typically rotates through 360 degrees infinitely. Such a rotating head may, according to certain aspects of the present invention, be used with system according to the present invention; but, in other aspects, a drag chain system 170 is used below the ring gear housing 150 and above the link adapter 180 to convey fluids and signals to components below the ring gear housing 150 (see, e.g., FIGS. 3B and 5 ). The drag chain system 170 does not permit infinite 360 degree rotation, but it does allow a sufficient range of motion in a first direction or in a second opposite direction to accomplish all the functions to be achieved by system components suspended from the link adapter 180 (e.g. an elevator and/or a pipe handler), in one aspect with a range of rotative motion of about three-quarters of a turn total, 270 degrees.
Optionally, instead of a typical rotating head or a drag chain system according to the present invention, a variety of known signal/fluid conveying apparatuses may be used with systems according to the present invention; e.g., but not limited to, wireless systems or electric slip ring systems, in combination with simplified fluid slip ring systems.
Enclosed within a system housing 171 is a rotatable spool 174 which is rotated by a chain 176 made up of a plurality of interconnected chain sections 177 . In one position the chain 176 is wound around the periphery of the spool 174 . As the chain 176 unwinds from the spool 174 as the spool 174 is rotated by the hydraulic motor 158 rotating the ring gear 152 , the unwinding chain portion feeds into the housing 171 in which it resides until the spool 174 is rotated in the opposite direction and the chain 176 is again wound onto the spool 174 .
As the chain 176 winds and unwinds, hoses and cables 178 wind and unwind with the chain 176 . Sections 177 of the chain 176 have openings 179 through which pass the hoses and cables 178 so that the chain 176 supports the hoses and cables 178 and maintains them in an organized, untangled arrangement with respect to the spool 174 , both at rest and when the spool 174 is being rotated. One end of the chain 176 is secured to the spool 174 . The hoses and cables 178 project out from the spool 174 and extend downwardly to components of the system (one such item illustrated in FIG. 3B as hose or cable 178 a ).
Fasteners 183 secure the spool 174 to the link adapter 180 . The combination of the spool 174 and ring gear 152 (and, therefore, the link adapter 180 and whatever is suspended from it) is permitted some limited degree of vertical movement due to the dimensions of the ring gear housing 150 and the ring gear 152 —the ring gear 152 can move up and down within the housing 150 , e.g., in one particular aspect, about 0.25 inch, and the link adapter 180 can move a limited distance (a load ring/link adapter gap 181 ) with respect to a load ring 184 as described in detail below.
A spring cartridge apparatus 182 with a top ring 182 a and a bottom ring 182 b has plurality of spaced-apart springs 188 which urge the two rings apart (see, e.g., FIGS. 3B and 6 ). The spring cartridge 182 is within the link adapter 180 and surrounds a stem 186 that is secured with bolts 185 to the gear housing 140 . A ring 189 projecting into the wall of the stem 186 projects outwardly therefrom and supports the spring cartridge apparatus 182 . The stem 186 acts as a guide for movement of the link adapter 180 , maintains centering of the link adapter 180 , and supports the link adapter 180 , via the spring cartridge apparatus 182 , during certain operations, e.g., drilling.
The springs 188 within the spring cartridge 182 push upwardly on the spool 174 , lifting the spool 174 and maintain the gap 181 between the link adapter 180 and the load ring 184 (secured to the main shaft with a split ring 167 ); so that, e.g., during drilling, the main shaft 160 can rotate independently of the link adapter 180 and whatever is connected thereto. The springs 188 can support the weight of the link adapter, the links (or bails) connected to the link adapter, and an elevator apparatus. When tubular(s) are engaged by the elevator apparatus, the springs 188 collapse, the link adapter 180 moves down to rest on the load ring 184 , the load then passes to and through the main shaft 160 . Thus, the link adapter 180 (and whatever is connected thereto) can be maintained stationary while drilling. When a sufficient load is placed on the link adapter 180 (e.g. when hoisting the drillstring with an elevator or running casing), the forces of the springs 188 are overcome, the link adapter 180 is moved down to close the gap 181 , and the link adapter 180 rests on the load ring 184 so that the link adapter load is transferred to the load ring 184 .
Thus, certain systems according to the present invention provide two ways to transfer the load of tubular(s) supported by the system: first, the load of tubulars connected to the main shaft passes from the main shaft, to the quill, to the main thrust bearings, to the main body, to the bails, to the becket, to the hook and/or block, and to the derrick; and, secondly, when a string, e.g. a drillstring, is being raised or lowered without being rotated (e.g. when tripping pipe or lowering casing) the tubular load passes from a tubular support (e.g. an elevator) to the link adapter, to the load ring, to the split ring 167 and thence to the main shaft, and thence, as in the first load transfer path described above, to the derrick.
Drilling loads (the load of the drillstring, bit, etc.) passes through a threaded connection at the end of the main shaft 160 to the main shaft 160 . Tripping loads (the load, e.g., of tubular(s) being hauled and manipulated) pass through the link adapter 180 and through the load ring 161 , not through the threaded connection of the main shaft and not through any threaded connection so that threaded connections of the top drive are isolated from tripping loads.
In certain aspects as compared to certain prior system, the spring cartridge 182 with the plurality of springs 188 is a simpler, passive apparatus which requires relatively less maintenance and can result in reduced system downtime.
The main shaft can be removed from the system 100 , to repair the main shaft or to replace the main shaft, without disturbing and without removing the gear case and gearing of the system. To remove the main shaft, the bonnet, gooseneck, washpipe, and associated packing are removed, preferably together as a unit. The bolts 164 that hold the main shaft down are removed. The split ring 167 is removed. The main shaft is disconnected from the quill. After the load ring and the split ring are removed, the main shaft is then removed from the system. During this removal process, all the system gearing and seals have remained in place and no lubricant has been removed or drained.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a motor apparatus; a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable; a quill connected to and around the main shaft; a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft, the main shaft passing through the gear system; upper components connected to the main body above the top end of the main shaft; and the main shaft removable from the top drive system by disconnecting the main shaft from the quill, by disconnecting the upper components from the main body and moving the upper components from above the main shaft, and by lifting the main shaft from the quill.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a motor apparatus; a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable; a quill connected to and around the main shaft; a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft, the main shaft passing through the gear system; a link adapter having a central bore therethrough, the main shaft passing through the central bore of the link adapter; a load ring connected to the main shaft; the link adapter positioned above the load ring; upper components connected to the main body above the top end of the main shaft; and the main shaft removable from the top drive system by disconnecting the main shaft from the quill, by disconnecting the load ring from the main shaft, by disconnecting the upper components from the main body, and by lifting the main shaft from the quill. Such a system may have one or some, in any possible combination, of the following: wherein the upper components include a bonnet connected to the main body, a washpipe in fluid communication with the top end of the main shaft, a gooseneck in fluid communication with the washpipe, and the upper components are movable from above the main shaft; wherein the gear system is in lubricant within an enclosed space and the main shaft is removable without lubricant draining from the enclosed space; wherein the quill is connected to the main shaft with first connectors through which tension on the main shaft is transferred to the quill, and with second connectors through which torque is transferred from the quill to the main shaft; two spaced-apart bails, each bail with two spaced-apart lower ends, and each lower end connected to the main body thereby providing a four-point connection between the bails and the main body for the bails to support the top drive system; a spring cartridge apparatus having a top ring, a bottom ring, a plurality of springs positioned between and urging apart the top ring and the bottom ring, the spring cartridge apparatus located within the link adapter and urging the link adapter away from the load ring so that a gap is maintained between the link adapter and the load ring until sufficient weight is supported by the link adapter to overcome the urging of the springs; a drag chain system for allowing rotation of the link adapter, the drag chain system including a housing, a spool rotatably mounted within the housing, a chain with a first end and a second end, the first end connected to the spool, the second end connected to the link adapter, the chain able to be wound onto and unwound from the spool, unwound chain received within the housing, a plurality of conduits carried by the chain, the conduits for transmitting signal or power fluids between the drag chain system and items below the link adapter, and a rotation system connected to the spool for rotating the spool and the link adapter; wherein the rotation system includes a ring gear housing, a ring gear rotatably mounted in the ring gear housing, a gearing system interconnected with the ring gear, a motor for driving the gearing system to rotate the ring gear to rotate the spool and the link adapter, winding and unwinding the chain as the link adapter is rotated; and/or wherein the rotation system includes locking apparatus for selectively preventing rotation of the ring gear thereby selectively preventing rotation of the link adapter.
FIG. 7 shows a typical prior art drilling system with a derrick DK supporting a top drive TD which rotates drill pipe DP. The top drive is supported from a travelling block TB beneath a crown block CB. A drawworks, DS, on a rig floor RF raises and lowers the top drive. The top drive moves on a guide track GT.
FIG. 8 shows a system S according to the present invention with a top drive 201 with a drive motor 202 ; a gear system 203 coupled to the top drive 201 with a bearing support 204 and support links 204 a ; a washpipe apparatus 209 ; a gooseneck 214 ; an elevator load ring 205 ; a mud saver system 211 ; a lower internal blowout preventer 206 ; a saver sub 207 ; a top drive main shaft 212 ; a pipe gripper 208 with support 208 a ; and a seal system 210 (shown schematically) according to the present invention.
FIG. 9 illustrates components for a system 210 e.g., as in FIG. 8 (like numerals indicate like parts). One embodiment of the seal system 210 for a main shaft 212 of the top drive system S has a primary seal 214 on a support 216 of a seal carrier 220 that seals against a lower exterior surface 218 a of a seal ring 218 . The seal carrier 220 is bolted with bolts 213 to a support member 224 which is connected adjacent structure of the top drive. Fluid, (e.g. oil, lubricant in a gear box or housing 226 ) is prevented from going past this seal 214 . Optionally, a split ring 230 with a connecting bolt 231 (or bolts) hold the seal ring 218 on the shaft 212 ; or the seal ring is secured directly to the shaft. Optionally, the seal ring itself can be fixed or adhered to the main shaft with an interference fit, suitable fasteners, connectors, and/or adhesives, with or without the split ring 230 . Seals 223 a and 223 b seal a member- 224 /carrier- 220 interface.
The support 216 is bolted to (or formed integrally of) a body 242 . The bolt 213 secures the support 216 to the support member 224 . The support 216 and body 242 are movable up and down by rotating the bolt 213 (multiple bolts may be used).
Part of a typical lower radial bearing apparatus 250 is above the support member 224 . A main thrust bearing apparatus 252 is located within the box or housing 226 (shown schematically in dotted lines). The lubricating oil for these bearings is maintained on these bearings without leaking past the seal system 210 .
A secondary seal 234 is secured to the body 242 (e.g. by an interference fit, fastener(s), and/or adhesives). The secondary seal 234 does not initially contact the surface 218 a since it is smaller in diameter than the primary seal 214 . In order to utilize the secondary seal 234 to seal against the seal ring 218 , the bolt 213 (or bolts) is turned to raise the support 216 and the body 242 so that the secondary seal 236 is moved adjacent a secondary surface 218 b of the seal ring 218 . The secondary surface 218 b has a larger diameter than the surface 218 a so that when the secondary seal 235 is raised, it sealingly contacts the secondary surface 218 b . Optionally, additional seal(s) like the seal 234 are positioned above the seal 234 and the seal ring 218 has additional sealing surfaces for the additional seal(s) to sealing contact when the seal(s) are raised into seating position. Each additional seal surface (higher than the preceding seal surface) has a larger diameter than the preceding (lower) seal surface and each additional seal (higher than the preceding seal) has a smaller diameter than the preceding (lower) seal. It is to be understood that FIG. 9 illustrates one half of the seal system 210 (on the left side in FIG. 9 ) and that ring, seals, etc. on the right side (not shown) mirror the left side. The seal 214 inhibits the flow of debris and contaminants to the seal 234 . In one aspect the seal 234 is within the space of the housing 226 and is bathed in lubricant, further protecting the seal 234 until it is used.
It is within the scope of the present invention to provide a seal ring 218 with two (as shown) surfaces (one a stepped surface) or with three, four or more such steps and with three, four, or more corresponding additional secondary seals.
FIGS. 10A-10C show a seal system 300 according to the present invention for sealing against a quill 352 (shown partially) of a top drive system. The quill 352 is connected to a top drive main shaft 362 (connection not shown) and the quill 352 rotates with the main shaft 362 . The quill 352 has an exterior surface 354 and a primary seal 302 of the seal system 300 sealing contacts this exterior surface 354 .
The quill 352 has a circumferential groove 356 and a secondary seal 304 , as shown in FIGS. 10A and 10B , is adjacent the groove 356 and is not yet in contact with the quill 352 . The seals 302 , 304 are circumferential seals that extend around the circumference of the quill 352 . A seal 316 seals a carrier- 310 /member- 315 interface.
The seals 302 and 304 are secured to a seal carrier 310 . Rotatable bolts 312 (or a single bolt) rotatably connected to the seal carrier 310 project through a member 314 (e.g., but not limited to a stem associated with a lower link adapter). Rotating the bolts 312 moves the seal carrier 310 down with respect to a member 315 , as shown in FIG. 4C , to move the secondary seal 304 down past the groove 356 until the seal 304 sealingly contacts the exterior surface of the quill 352 . Optionally and/or alternatively, the bolt(s) 312 are rotatable to raise the seal carrier 310 to move the seal 304 up into sealing contact with the quill 352 (with sufficient space provided above the seal carrier to accomplish this).
Gearing 360 of the top drive, driven by a top drive motor (not shown) is connected with and drives the quill 352 (which drives the main shaft 362 ). Lubricant for the gearing 360 is prevented from flowing down by the seal system 300 .
Optionally and/or alternatively, the groove 356 is on the main shaft and the seal system is located so that seal system's seals seal against the main shaft (with or without a quill).
Optionally and/or alternatively, a seal carrier according to the present invention may have a threaded outside diameter that threadedly mates with a corresponding threaded part adjacent a rotating shaft so that the seal carrier may be moved up or down with respect to the shaft by rotating the seal carrier and moving it up or down as the seal carrier's threads engage the adjacent part's threads.
As shown in FIG. 9A , a system 210 a (like the system 10 , FIG. 3 ; like numerals indicate like parts) has a seal carrier 220 a with a threaded side 220 b which threadedly mates with threads 224 b of a support member 224 a . Rotating the seal carrier 220 a moves the seal 234 up to sealingly contact the surface 218 b.
As shown in FIG. 10D , a system 300 a (like the system 300 , FIG. 10A ; like numerals indicate like parts) has a seal carrier 310 a with a threaded side 310 b that threadedly mates with threads 315 b of a member 315 a . Rotating the seal carrier 310 a moves the seals 302 , 304 with respect to the quill 352 and its groove 356 . Rotating the seal carrier 310 a in either direction sufficiently will move the seal 304 into sealing contact with the quill 352 .
The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: motor apparatus; a main shaft having a top end and a bottom end; a gear system driven by the motor apparatus and interconnected with the main shaft for driving the main shaft; a sealing assembly adjacent the main shaft for sealing against the main shaft, the sealing assembly having a seal carrier adjacent the main shaft, a primary seal member on the seal carrier, the primary seal member sealingly contacting the main shaft, at least one secondary seal on the seal carrier, and the seal carrier selectively movable to move the at least one secondary seal into sealing contact with the main shaft. Such a system may have one or some, in any possible combination, of the following: wherein the main shaft has a seal ring connected to the main shaft, the seal ring having a first portion with a first diameter and a second portion with a second diameter the first diameter smaller than the second diameter, the primary seal member is sealing contact with the first portion of the seal ring, the secondary seal member adjacent the second portion of the seal ring, and the seal carrier movable to move the secondary seal into sealing contact with the second portion of the seal ring; a retainer releasably securable to the main shaft to hold the seal ring in place; wherein the seal carrier is releasably secured to part of the top drive adjacent the main shaft with at least one rotatable bolt threadedly mated with the part of the top drive so that rotating the at least one bolt moves the at least one secondary seal into sealing contact with the main shaft; and/or wherein the seal carrier has a carrier threaded surface and part of the top drive system adjacent the main shaft has a part threaded surface, the seal carrier rotatable with the carrier threaded surface threadedly engaging the part threaded surface so that the seal carrier is movable to move the at least one secondary seal into sealing contact with the main shaft.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: motor apparatus; a main shaft having a top end and a bottom end; a gear system driven by the motor apparatus and interconnected with the main shaft for driving the main shaft; a sealing assembly adjacent the main shaft for sealing against the main shaft, the sealing assembly having a seal carrier adjacent the main shaft, a primary seal member on the seal carrier, the primary seal member sealingly contacting the main shaft, at least one secondary seal on the seal carrier, and the seal carrier selectively movable to move the at least one secondary seal into sealing contact with the main shaft. Such a system may have one or some, in any possible combination, of the following: wherein the main shaft has a seal ring connected to the main shaft, the seal ring having a first portion with a first diameter and a second portion with a second diameter the first diameter smaller than the second diameter, the primary seal member is sealing contact with the first portion of the seal ring, the secondary seal member adjacent the second portion of the seal ring, and the seal carrier movable to move the secondary seal into sealing contact with the second portion of the seal ring; a retainer releasably securable to the main shaft to hold the seal ring in place; wherein the seal carrier is releasably secured to part of the top drive adjacent the main shaft with at least one rotatable bolt threadedly mated with the part of the top drive so that rotating the at least one bolt moves the at least one secondary seal into sealing contact with the main shaft; and/or wherein the seal carrier has a carrier threaded surface and part of the top drive system adjacent the main shaft has a portion with a mating, threaded surface, the seal carrier rotatable with the carrier threaded surface threadedly engaging the part's mating threaded surface so that the seal carrier is movable to move the at least one secondary seal into sealing contact with the main shaft.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a seal system for sealing against a shaft, the seal system including: a first surface area on a shaft, the shaft being generally cylindrical; at least one second surface area on the shaft; the first surface area and the at least one second surface area on the shaft extending circumferentially around the shaft; the first surface area having a diameter different from a diameter of the at least one second surface area; a seal carrier; a first seal on the seal carrier, the first seal in sealing contact with the first surface area of the shaft; at least one second seal on the seal carrier, the at least one second seal initially not in contact with the shaft; and the seal carrier movable to move the at least one second seal into sealing contact with the at least one second surface area. Such a system may have one or some, in any possible combination, of the following: the first surface area has a diameter smaller than the at least one second surface area; the first surface area has a diameter equal to the second surface area, the shaft has a circumferential groove therearound and the at least one second seal is initially adjacent and not in contact with the groove, the seal carrier movable to move the at least one second seal into sealing contact with the second surface area; wherein the seal carrier is releasably secured to a part of a mechanical system including the shaft with at least one rotatable bolt threadedly mated with the part so that rotating the at least one bolt moves the at least one secondary seal into sealing contact with the shaft; and/or wherein the seal carrier has a carrier threaded surface and a part of a mechanical system adjacent the shaft has a part threaded surface, the seal carrier rotatable with the carrier threaded surface threadedly engaging the part threaded surface so that the seal carrier is movable to move the at least one secondary seal into sealing contact with the shaft.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for sealing against a shaft of a mechanical system, the mechanical system including motor apparatus, a shaft having a top end and a bottom end, a gear system driven by the motor apparatus and interconnected with the shaft for driving the shaft, a sealing assembly adjacent the shaft for sealing against the shaft, the sealing assembly having a seal carrier adjacent the shaft, a primary seal member on the seal carrier, the primary seal member for sealingly contacting the shaft, a second seal on the seal carrier, the second seal not initially in contact with the shaft, and the seal carrier selectively movable to move the second seal into sealing contact with the shaft, the method including: locating the seal carrier so that the primary seal sealingly contacts the shaft, and moving the seal carrier so that the second seal sealingly contacts the shaft. Such a method may have one or some, in any possible combination, of the following: wherein the shaft is a main shaft driven by the motor; wherein the shaft is a quill of a top drive system positioned around and connected to a main shaft of the top drive system, the gear system connected with the quill to drive the quill to drive the main shaft; wherein the mechanical system is a top drive system for wellbore operations; and wherein the shaft is a main shaft driven by the motor.
In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
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A top drive system for wellbore operations, the top drive system including motor apparatus, a main shaft driven by the motor apparatus, the main shaft having a top end and a bottom end, a quill connected to the main shaft, a gear system interconnected with the quill and the motor apparatus, and a multi-seal system for sealing against the quill. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
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[0001] This application claims priority from co-pending U.S. provisional application serial No. 60/363,458, filed on Mar. 12, 2002, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Piperazines of formula A
[0003] wherein R is a lower alkyl, Ar is an unsubstituted or substituted aryl or heteroaryl, and Q is a hydrogen, CO-(lower) alkyl, CO-cycloalkyl, or CO-aryl, are potent 5HT1A receptor binding agents. U.S. Pat. No. 6,127,357 teaches such piperazine derivatives that are useful in the treatment of Central Nervous System (CNS) disorders. Piperazine derivatives of formula A contain an asymmetric carbon so they may exist in two optically active forms. It is now well understood that enantiomers bind to receptors with different potency and selectivity, they may have different metabolic fate and produce different side effects. WO 9703982 teaches that preferred enantiomers of piperazines of formula A display improved 5HT1A binding affinity and bioavalability. Therefore, an efficient, operationally facile, inexpensive and safe alternative process for making these homochiral piperazines is desirable.
[0004] WO 9533725 teaches a method for synthesizing some chiral piperazines of formula A by alkylation of the corresponding 1-aryl-piperazine with enantiomerically pure 2-(5-methyl-2,2-dioxido-1,2,3-oxathiazolidin-3-yl)pyridine.
[0005] One conventional approach to creating 1,4-disubstituted piperazines is via bis-alkylation of primary amines with bis(2-chloroethyl) amines, the so-called nitrogen mustard gases. A few optically active piperazines, structurally unrelated to formula A, have been prepared by condensation of an N-substituted bis(2-chloro-ethyl)amine with a selected chiral amine according to Natsuka et al. in J.Med.Chem. 1987, 1779 and WO 9424115, and with a natural amino acid according to Acta Pol. Pharm. 1999, 56, p. 41; CA 131: 157745. However, there is a need for a process to make synthetically useful, chiral nitrogen mustard molecules. Chem. & Pharm. Bulletin Japan 1954, 275 describes a conversion of bis(2-chloroethyl)amine into N-bis(2-chloroethyl) aminoacetonitrile, and a related paper in Chem. & Pharm. Bulletin Japan 1957, 487 reports an unsuccessful attempt to resolve the corresponding racemic N-bis(2-chloroethyl)alanine, and tedious resolution of 2-[N-bis(2-chloro-ethyl)amino]propanamide.
[0006] Polyfunctional chiral amines are accessible by several multi-step procedures, but a direct displacement of a reactive functional group typically results in racemic amines.
[0007] Effenberger et al. (Angew. Chem. 1983, 95[1], 50) reported that triflates react with simple secondary amines under Walden inversion. This process was applied to the syntheses of both (R)- and (S)-α-amino acid esters. The method allows asymmetric formation of C(α),N-bond in a single reaction with a high degree of stereoselectivity, and has been occasionally used with minor modifications (Quadri et al., Biorg. & Med. Chem. Letters 2, 1661, 1992; Taylor et al., Tetrahedron Letters 37, 1297, 1996). Hoffman and Hwa-Ok Kim, Tetrahedron Letters 31, 2953, 1990 replaced triflates with (4-nitrobenzene)sulfonyloxy esters in a reaction with hydrazines.
SUMMARY OF THE INVENTION
[0008] The present invention comprises a process for the preparation of a compound of formula III
[0009] wherein R and R′ each independently represents a C 1 -C 3 alkyl group; Ar represents a dihydrobenzodioxinyl or benzodioxinyl, or phenyl optionally substituted with up to three substituents independently selected from halogen, methoxy, halomethyl, dihalomethyl and trihalomethyl; said process comprising reacting a compound of formula la and a compound of formula Ib to form a compound of formula II,
[0010] and further reacting the compound of formula II with an aryl amine compound, Ar—NH 2 , in which Ar is defined as stated above, to produce a compound of formula III. Preferably, these steps are performed in a concatenated manner to form compound III without isolating intermediate compound II.
[0011] In a preferred embodiment, the compound of formula Ia is a single enantiomer, (S) or (R), that leads to the formation of a single enantiomer of a compound of formula II having an inverted configuration, i.e. (R) or (S). Hydride reduction of compound, of formula III then proceeds with retention of configuration to form the intermediate compound of formula IV.
[0012] The invention further comprises the reaction of a compound of formula IV to form the intermediate compounds of formulae V:
[0013] where X is a leaving group such as halo (especially chloro and bromo), methansulfonyloxy,
[0014] p-toluenesulfonyloxy, or p-bromophenylsulfonyloxy.
[0015] The invention also comprises the novel compounds represented by formulae II, III, iV and V, and the optical isomers thereof.
[0016] The invention also comprises the following process steps, in which compound V is used to make compounds VII, VIII and IX: treating the compound of formula V with a compound of formula VI in an aprotic solvent
[0017] wherein M is an alkali metal (e.g., Na, Li, K) and Y represents a moiety selected from the group consisting of C 1 -C 6 alkoxy, C 1 -C 6 alkyl, C 3 -C 7 cycloalkyl and C 3 -C 7 cycloalkoxy;
[0018] treating the compound of formula VII with a protic acid to form a compound of formula VIII
[0019] and, treating the compound of formula VIII with an aroyl compound selected from aroyl chloride, aroyl bromide and aroyl anhydride, in the presence of a base, to form a compound of formula IX
[0020] wherein Aryl represents a C 6 -C 12 aromatic group optionally substituted with up to three substituents independently selected from the group consisting of halogen atoms, alkyl, alkoxy, alkoxycarbonyl, nitro, amino, alkylamino, dialkylamino, haloalkyl, dihaloalkyl, trihaloalkyl, nitrile and amido substituents each having no more than six carbon atoms.
DETAILED DESCRIPTION
[0021] The present invention provides a process for preparing specific enantiomeric compounds as intermediates in the formation of 1,4-disubstituted piperazines that are useful as serotonin 1A receptor-binding agents. Chiral nitrogen mustard derivatives serve as primary reactants. This process results in a simpler reaction sequence than was previously known. The novel synthesis of chiral 1,4-disubstituted piperazines generates storage stable, synthetic intermediates for compounds of formula IX, shown above.
[0022] Various aspects of a preferred embodiment of the present invention are shown in Scheme 1:
[0023] Referring to Scheme 1, (S)-2-[(methylsulfonyl)oxy]propionate is commercially available, or such lactate triflates can be readily prepared from the corresponding alkyl lactates, for example according to the procedures of Prasad et al., J. Chem. Soc. Perkin Trans I, 1991, 3331, and Wang and Xu, Tetrahedron 54, 12597, 1998. Bis(2-chloroethyl)amine is liberated as a free base from its hydrochloride salt. The reaction of the first step in Scheme 1 is conducted in an inert organic solvent in which the starting materials are soluble, such as tetrahydrofuran, dioxane, 1,2-dimethoxyethane, diethyl ether, tert-butyl methyl ether, methylene chloride, chlorobenzene, trifluoromethylbenzene, or toluene. The temperature is not critical, and suitably may be from 0° C. to about 50° C., preferably between ice-bath and room temperature. Higher temperatures promote an undesirable elimination process. The reaction is generally run for 4-6 hours, although prolonged stirring times of up to 18-24 hours are not detrimental. Yields of the corresponding compound of formula II may be as high as 83%, but more typically, yields are in the range of 50-65%. Tetrahydrofuran is an optimum solvent, however, it is very sensitive to the presence of traces of triflic acid or triflic anhydride that may initiate partial tetrahydrofuran polymerization, and the resulting gelatinous material complicates isolation of the product.
[0024] A preferred embodiment of this invention comprises a one-step process wherein compound II is prepared in chlorobenzene as a crystalline triflic salt and is used to alkylate 2,3-dihydro-1,4-benzodioxin-5-amine in chlorobenzene to form compound III. The compound of formula II may be reacted with 2,3-dihydro-1,4-benzodioxin-5-amine in refluxing chlorobenzene for a period about 8 to about 18 hours. The formation of the compound of formula III thus may be effected in a concatenated manner by using a chlorobenzene solvent and continuing without a necessity for interim isolation of the compound of formula II.
[0025] An aminoester of the compound of formula III can be isolated as a free base or converted to a stable hydrochloride salt. Alternatively, the compound of formula III is obtained by condensation of 2,3-dihydro-1,4-benzodioxin-5-amine with a free base of compound of formula II under similar conditions, and both intermediates II and III are used in a crude state in the subsequent steps.
[0026] A preferred embodiment for formation of the compound of formula III from the compound of formula II comprises the reaction with amino-benzodioxine as illustrated in Scheme I. In another embodiment of this invention, an amino-phenyl is used instead of the amino-benzodioxane, wherein the phenyl may be substituted with up to three substituents independently selected from halogen, methoxy, halomethyl, dihalomethyl and trihalomethyl.
[0027] Intermediates of the compound of formula III can be reduced to the alcohol of formula IV by the use of reducing agents. The reaction is performed by conventional methods well known to those skilled in art, for example by using a complex metal hydride or a boron reducing agent under non-epimerizing conditions.
[0028] In a preferred embodiment of the process of this invention, the reduction is carried out under reflux in ether or in tetrahydrofuran at 20-40° C., using lithium aluminum hydride. The enantiomeric purity of the isolated alcohol IV is 98% or greater, as determined on a chiral column using a sample of racemic IV as reference.
[0029] In a further aspect of this invention, the alcohol of the compound of formula IV may be treated with methanesulfonyl chloride in the presence of an organic base in methylene chloride to produce the intermediate compound of formula V. In an alternative embodiment, the alcohol of formula V or its hydrochloride salt is heated with thionyl chloride in refluxing chloroform to obtain a hydrochloride salt of the compound of formula V.
[0030] Depending on the nature of the leaving group X, acidity of the medium, concentration, or solvent polarity, these piperazines may exist in an equilibrium with 6-aza-3-azoniaspiro[2,5] octane species.
[0031] The present invention further comprises the novel compounds of formula II, III, and IV. Preferred embodiments thereof include: N,N-bis(2-chloroethyl)-(R)-alanine methyl ester, trifluoromethanesulfonate; N,N-bis(2-chloroethyl)-(R)-alanine ethyl ester, trifluoromethanesulfonate; (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid ethyl ester; (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-ethyl-1-piperazineacetic acid ethyl ester;
[0032] (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid methyl ester; (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-ethyl-1-piperazineacetic acid methyl ester;
[0033] (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineethanol; and, (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-ethyl-1-piperazineethanol.
[0034] Compound V can be reacted with a compound of formula VI to form a compound of formula VII. Y represents a moiety selected from the group consisting of C 1 -C 6 alkoxy, C 1 -C 6 alkyl, C 3 -C 7 cycloalkyl and C 3 -C 7 cycloalkoxy.
[0035] The aminopyridyl functionality is introduced via displacement. It is not apparent from the prior art how seriously the side reactions described above can threaten the usefulness of this displacement. Much depends on the specific alkylating reagent. In WO9703982, an aminopyridine Via, under unspecified conditions, can be treated with generic compounds Va, where X is a leaving group, to give VIIa. In the course of developing this invention, we have observed that the anion of N-alkanoyl compounds (i.e., VIb) reacts with V (X=Cl) to give a significant quantity (ca. 20%) of undesired alkylation on the pyridyl nitrogen, forming compound X. In a preferred embodiment of the present invention, Y is an alkoxy group, more preferably C 1 -C 6 alkoxy.
[0036] This invention provides a practical synthesis of N-aryl piperazines where chirality is introduced at the piperazine ring formation step and 2-aminopyridyl substitution is incorporated via displacement.
[0037] The use of t-Boc 2-amino pyridine, VI, as described in this invention significantly suppresses the amount (<7%) of analogous by-product formed, increasing the proportion of desired compound VII. As shown in the preceding section, the t-Boc protecting group is easily removed and the freed amine can be then acylated.
[0038] Throughout this specification and in the appended claims, except where otherwise indicated, the terms halogen and halo refer to F, Cl and Br, and the terms alkyl, alkane, alkanol and alkoxy include both straight and branched chain alkyl groups.
[0039] The following examples are presented to illustrate certain embodiments of the present invention, but should not be construed as limiting the scope of this invention.
EXAMPLE I
N,N-Bis(2-chloroethyl)-(R)-alanine ethyl ester, trifluoromethanesulfonate
[0040] A suspension of bis(2-chloroethyl)amine hydrochloride (0.392 g; 2.1 mmol) in 5N aqueous sodium hydroxide (3 mL) is extracted with ether (2×10 mL) and the combined extracts are washed with a minimum amount of water and saturated brine. The ethereal solution is dried quickly over magnesium sulfate and filtered. Tetrahydrofuran (2 mL) is added to the filtrate, and ether is carefully removed under reduced pressure on a rotavapor unit without heating. The residue is mixed with a solution of ethyl (S)-2-[(methylsulfonyl)oxy]-propionate (0.5 g; 2 mmol) in tetrahydrofuran (1 mL). After stirring the reaction mixture for 24 hrs at room temperature, there is no visible precipitate. The volatiles are removed under reduced pressure and the remaining viscous oil is dissolved in ether (8 mL), and the slightly turbid solution is filtered after 60 minutes. The filtrate is treated dropwise with n-heptane to induce crystallization; the final ratio of n-heptane/ether is 1:3. The crystalline salt is collected by filtration and washed quickly with a small portion of ether. There is obtained 0.653 g (yield 83.3%) of N,N-bis(2-chloroethyl)-(R)-alanine ethyl ester, trifluoromethanesulfonate; mp 73-74.5° C.; 1 H NMR (300 MHz, CDCl 3 ) δ 1.35 (t, J=7.1 Hz, 3H), 1.76 (d, J=7.2 Hz, 3H), 3.87 (m, 2H), 4.00 (m, 2H), 4.35 (q, J=7.1 Hz, 2H), 4.57 (q, J=7.2 Hz, 1 H), 9.02 (b, 1H).
EXAMPLE II
(R)-4-(2,3-Dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid ethyl ester
[0041] A solution of 2,3-dihydro-1,4-benzodioxin-5-amine (0.327 g; 2.16 mmol) in chlorobenzene (2 mL) is added to a solution of N,N-bis(2-chloroethyl)-(R)-alanine ethyl ester (trifluoromethanesulfonic acid salt; 0.850 g; 2.16 mmol) in the same solvent (2 mL). The stirred reaction mixture is heated at 130° C. for 15 hours, the volatiles are removed on a rotavap, and the semi-solid residue is partitioned between 10% sodium bicarbonate (15 mL) and ether. Organic extracts are washed with brine, dried over magnesium sulfate, and filtered. TLC (chloroform) shows formation of a new product with R F 0.15, (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid ethyl ester. Upon addition of 1 N ethereal HCI, (R)-4-(2,3-dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid ethyl ester is converted into its hydrochloride salt that is collected by filtration; 0.615 g (80%), mp 168-171° C. The salt can be recrystallized from ethanol-ether, or acetone-ether. 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.25 (t, J=7.1 Hz, 3H), 1.58 (d, J=7.2 Hz, 3H), 3.16 (m, 2H), 3.36 (m, 2H), 4.23 (m, 4H), 4.26-4.38 (m, 3H), 4.48 (b, 4H), 6.52 (d, J=7.9 Hz, 1H), 6.57 (d, J=8 Hz, 1H), 6.76 (t, J=8 Hz, 1H), 11.3 (b, <1H).
[0042] EXAMPLE III
(R)-4-(2,3-Dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineethanol
[0043] The hydrochloride salt made by Example II (1.07 g; 3 mmol) is suspended in 5% aqueous sodium bicarbonate (6 mL) and extracted with ether. The organic phase is separated, washed with brine, dried quickly over magnesium sulfate and filtered. The filtrate is added to a stirred suspension of lithium aluminum hydride (0.34 g; 9 eq) and the mixture is heated to a mild reflux for 3 hours. After cooling, it is decomposed with water (1 mL) and 0.5N hydrochloric acid (7 mL). The aqueous layer is separated, basified with 10% sodium bicarbonate and re-extracted with ether. The combined extracts are washed with small amounts of water and brine, dried over magnesium sulfate, filtered and evaporated. The oily product (0.69 g; yield 82%) slowly crystallizes upon standing, and can be recrystallized from n-butanol/n-heptane; mp 92° C.; enantiomeric purity 98%; 1 H NMR (300 MHz, CDCl 3 ) δ 1.03 (d, J=7 Hz, 3H), 2.74 (m,2H), 2.97 (m, 3H), 3.14 (m, 4H), 3.42 (t, J=11 Hz,1H), 3.57 (dd, J=11 Hz, J 1 =5 Hz, 1H), 4.35 (sym m, 4H), 6.53 (d, J=7.9 Hz, 1H), 6.61 (d, J=7.9 Hz, 1H), 6.75 (t, J=7.9 Hz, 1H)
EXAMPLE IV
(R)-4-(2,3-Dihydro-1,4-benzodioxin-5-yl)-α-methyl-1-piperazineacetic acid ethyl ester
[0044] A free base of bis(2-chloroethyl)amine is liberated by partitioning its hydrochloride salt between 5N aqueous sodium hydroxide and methylene chloride, in an analogous manner to that used for Example I. The isolated bis(2-chloroethyl)amine (0.94 g; 6.56 mmol) is then added in two portions over 1 hour into a stirred solution of (S)-2-[(methylsulfonyl)oxy] propionate (0.82 g; 3.28 mmol) in chlorobenzene (10 mL) at room temperature. The reaction mixture is stirred for additional 2 hours, the solid precipitate is filtered off and washed with a small volume of chlorobenzene. The filtrate is mixed with a solution of 2,3-dihydro-1,4-benzodioxin-5-amine (0.46 g; 3 mmol) and the reaction mixture is heated to reflux for 18 hours. After cooling, the product is rendered basic with 5% aqueous sodium bicarbonate (20 mL) and extracted twice with ether (50 mL). The combined extracts are washed with water, brine, dried over magnesium sulfate, and filtered. The filtrate is concentrated in vacuo to give a crude product that can be directly reduced, or passed through a plug of silica gel in chloroform to obtain compound III (0.49 g; overall yield 50%). The material is identical to that described in Example II.
EXAMPLE V
(R)-4-(2,3-Dihydro-1,4-benzodioxin-5-yl)-β-methyl-i-piperazineethanol
[0045] A free base of bis(2-chloroethyl)amine (28.4 g; 0.2 mol) is liberated from its hydrochloride salt as described in Example IV and mixed with a solution of (S)-2-[(methylsulfonyl)oxy] propionate (20 g; 0.08 mol) in chlorobenzene (150 mL). The mixture is stirred for 3 hours at room temperature, and the resulting thick slurry is washed with water (100 mL) and 10% sodium bicarbonate (100 mL). The organic phase is transferred to a flask containing 2,3-dihydro-1,4-benzodioxin-5-amine (9.6 g; 0.064 mol) and the reaction mixture is allowed to reflux upon stirring for 18 hours. A small amount of yellow precipitate appears. The mixture is cooled to room temperature and agitated with 10% aqueous sodium bicarbonate (55 mL) for 1 hour. The organic layer is separated, dried over sodium sulfate, filtered, and concentra-ted in vacuo. The residue is dissolved in tetrahydrofuran (50 mL) and added dropwise to a stirred suspension of lithium aluminum hydride (9.1 g; 0.24 mol) in tetrahydrofuran (50 mL). The mixture is heated to 40° C. for 90 minutes, cooled, and decomposed by dropwise addition of ethyl acetate (200 mL). The product is then extracted with 2N hydrochloric acid (500 mL), the aqueous portion is washed three times with ethyl acetate (150 mL) and rendered basic with 10N sodium hydroxide to re-extract the product with ethyl acetate (2×200 mL). The combined extracts are washed with brine, dried over sodium sulfate, filtered and evaporated in vacuo. The residual oil crystallizes upon standing, and in TLC analysis (ethyl acetate-hexane 3:2) co-spots with the alcohol of Example III. Spectroscopic data and enantiomeric purity are identical to those presented in Example II. Overall yield 9.1 g (51%) based on 2,3-dihydro-1,4-benzodioxin-5-amine.
EXAMPLE VI
6-(2,3-Dihydro-1,4-benzodioxin-5-yl)-1-methyl-6-aza-3-azoniaspiro[2,5]octane chloride
[0046] A solution of the alcohol made according to Example III (0.5 g: 1.8 mmol) in methylene chloride (15 mL) is treated with triethylamine (0.2 g; 1.98 mmol). The mixture is stirred on a ice bath and a solution of methanesulfonyl chloride (0.24 g; 2.1 mmol) in methylene chloride (2 mL) is added dropwise. After 20 minutes, the ice bath is removed, and the reaction mixture is kept at room temperature overnight. The resulting solution is washed successively with a small amount of water, 5% aqueous sodium bicarbonate, and brine, then dried over magnesium sulfate and filtred. The volatiles are removed on a rotavap to give an oily product (0.5 g). 1 H NMR (300 MHz, CDCl 3 ) δ1.55 (d, J=7.2 Hz, 3H), 2.54 (dd, J=15 Hz, J 1 =7.5 Hz, 1H), 2.64-2.81 (m, 5H), 3.11 (m, 4H), 4.11 (sym m, 1H), 4.27 (m, 4H), 6.52 (d, J=7.8 Hz, 1H), 6.57 (d, J=8 Hz, 1 H), 6.76 (t, J=7.8 Hz, 1H)
EXAMPLE VII
(R)-4-(2,3-Dihydro-1,4-benzodioxin-5-yI)-1-(2-chloro-1 -methylethyl)piperazine
[0047] A solution of the alcohol made according to Example III (0.3 g: 1.08 mmol) in methylene chloride (5 mL) is acidified with ethereal HCl, the resulting solution is evaporated, and the semi-crystalline residue triturated with ether. After decanting, the material is crystallized from acetonitrile-ether, mp 207-210° C. This salt (0.35 g) is suspended in chloroform (6 mL), thionyl chloride (0.2 g) is added, and the mixture is subjected to reflux for 8 hours. The resulting solution is allowed to cool, volatiles are removed in vacuo, and the residue is stripped with toluene and dried. TLC (ethyl acetate-hexane 3:2) shows no alcohol starting material present. 1 H NMR (300 MHz, DMSO-d 6 ) δ1.56 (d, J=7 Hz, 3H), 3.45 (m, 6H), 4.64 (m, 2H), 4.75 (m, 1 H); the spectrum also shows the presence of the aziridinium species. The product can be used directly for alkylation of 2-(tert-butoxycarbonyl-amino) pyridine.
[0048] Many variations of the present invention not illustrated herein will occur to those skilled in the art. The present invention is not limited to the embodiments illustrate and described herein, but encompasses all the subject matter within the scope of the appended claims and equivalents thereof.
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A process for a stereoselective preparation of novel chiral nitrogen mustard derivatives useful in synthesizing optically active 1,4-disubstituted piperazines of formula:
wherein R, Ar, and Q are defined as set forth herein, and intermediate compounds therefor. The 1,4-disubstituted piperazines act as 5HT1A receptor binding agents useful in the treatment of Central Nervous System (CNS) disorders.
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BACKGROUND OF THE INVENTION
The subject-matter of the present invention is an intraoperative probe, specifically intended for direct-contact observations, including a head for housing the transducers and a portion of a handle or grip, as well as a cable for connecting the transducers to processing and/or displaying devices.
Probes of this type are particularly suitable to allowing observation of soft tissue sections by direct contact with the organ involved during a surgical operation.
These probes not only make it possible to accurately determine the position of the lesions in the organs involved as well as of the blood vessels, thus increasing the safety and reliability of the operations, they can also be used in vascular surgical procedures, helping surgeons to quickly recognized and identify major anatomical defects and technical imperfections requiring immediate action before completing the surgical procedure.
In state-of-the-art intraoperative probes of this type the transducer-carrying head and the portion of handle or grip form one integral part and have a predetermined shape; as a result, the probe's head always has the same orientation relative to the grip. Because of the consequent limitations on the use of the probe in various operating conditions, different types of probes are provided, with different predetermined shapes and head orientations of the head relative to the grip.
Therefore, the purpose of the present invention is to produce an intraoperative zone sic! of the type described above, in such a way as to make said probe easily adaptable, by extremely economical means, to different operating conditions, making it possible to use additional instruments that expand the range of applications of the probe itself.
SUMMARY OF THE INVENTION
The present invention achieves the above purposes by means of an intraoperative probe of the type described at the outset, where the portion of the handle is separate from the transducer-carrying head, said two parts being equipped with matching means of removable attachment.
Any means of removable attachment can be used, particularly the connector type, since one of said two parts has a connecting end, preferably not round in shape, while the other part has a matching connecting seat, which is annular in shape or is configured as an open ring, that is, one that is not round, at least not on the inside.
The portion of the handle or grip may be equipped with a means for housing the cable connected to processing and/or displaying devices.
As an additional characteristic feature, the transducer-carrying head of the probe has a basically cylindrical, elongated shape, the transducers being placed along an axial portion of the shell wall of said transducer-carrying head. This portion may be flat or have a predetermined curvature generated around an axis which is perpendicular to the axis of the probe's head, the shape of the connecting end being other than a round shape, such as a polygonal or similar shape, and its axis being oriented with a preset angle relative to the axis of the probe's cylindrical head.
The axis of the head portion and the axis of the connecting end form a 45° angle.
In particular, the axis of the transducer-carrying head and the axis of the connecting end lie on the same plane, which is parallel to the transducers'sensing direction, that is, to the plane which is perpendicular to the flat portion on which the transducers are arrayed, while at least one of the faces of the connecting end is parallel to said plane.
To further improve the variety of shapes that can be obtained by virtue of the different orientations of the probe relative to the handle, the connecting seat on the end of the handle, that is, the axis of said seat, is angled at approximately 30° relative to the remaining part of he handle itself, that is, to the axis of said remaining part.
The above arrangements make it possible to produce an intraoperative probe with a configuration that can be modified within a predetermined number of shapes.
In particular, when the connecting seat and the matching connecting end have a basically square shape, the probe can present four different configurations, corresponding to standard configurations commonly used for this type of probe. Consequently, it is possible to obtain a multiplicity of different configurations with one probe alone. The number of such configurations obviously can be increased by providing a connecting seat and connecting end with a higher number of facets.
The connecting cable runs from the connecting end of the transducer-carrying head, and the connecting seat, as well as the corresponding portion of handle or grip, have an open cross section which is basically U-shaped. The opening through which the cable is introduced should be on the outside of the handle with the connecting seat, with reference to the angle formed by said two parts, while the width of the cable-holding groove in the handle is designed to hold the cable there by virtue of a slight retentive action resulting from a compression and/or slight elastic deformation of the same. The cross section of the cable-holding groove preferably should be slightly C-shaped or in the shape of a sector of a circle with an angle greater than 180°, so as to allow insertion and removal of the cable by virtue of the elastic deformation of the same as well as of the handle.
However, the probe's handle may also consist of anatomically contoured elements that can be gripped by or attached to at least one finger of the hand. In a first embodiment of the invention, the connecting seat of the probe is laterally attached to an annular element that can be expanded, at least elastically; such element having an open-ring section with an angle greater than 180° and being the element for elastic engagement with one finger of the hand.
Opposite the connecting seat, the gripping element has a transversal widening designed to accommodate two fingers, on the side of the back and/or the palm of the hand. In particular, said gripping element has a basically T-shaped section, where the two lateral grooves are rounded, or a section shaped as a double C, where the two Cs are side by side facing opposite directions, that is, with their open sides pointing away from each other.
By virtue of the angle between th e axis of the connecting end and the probe's transducer-carrying head, this type of finger-fitting grip also allows for different configurations of the handle-probe assembly, in a fashion similar to what has been described above with reference to the handle.
The handle and/or the additional different grips that can be associated with the probe's transducer-carrying head are also equipped with means of removable attachment to surgical instruments or additional accessories.
In particular, said means of attachment may be a connector, lock-joint or matching shape type of coupling.
In a preferred embodiment, needle-guiding elements for a biopsy needle can be attached to the handle, in particular to the outside of the connecting seat on the probe's head.
Said elements can be attached to the handle in a removable fashion by means of a slide, and have a needle-supporting guide on the external periphery as well as on the side of the connecting seat opposite the handle itself. Said guide consists of a groove that basically runs parallel to the axis of the connecting seat for the transducer-carrying head. The axis of the needle-guiding groove can advantageously lie on the same plane containing the axis of the handle and the connecting seat, and can also present on said plane a preset angle relative to the axis of said connecting seat for the transducer-carrying head.
The advantages of the present invention are apparent in the above description. This particular probe configuration makes it possible to provide for a set of holding and gripping accessories, as well as couplings for additional elements that can be attached as modules to a transducer-carrying head, so as to obtain an extremely economical and versatile probe whose functions or range of applications can easily be integrated over time and according to the particular needs.
The probe according to the present invention has additional characteristics, as claimed below.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics of the invention and the corresponding advantages can be seen more clearly in the following description of some embodiments, presented as nonrestrictive examples and illustrated in the attached drawings, where:
FIGS. 1 to 5 show different views of the probe's head according to the invention.
FIGS. 6 to 10 show different views of the probe's handle according to the invention.
FIGS. 11 to 14 show a side view of different configurations for coupling the probe's head with the handle, designed in accordance to the preceding figures, said configurations corresponding to standard configurations of intraoperative probes.
FIG. 15 shows a probe configuration particularly suited to attachment of an accessory such as a needle guide for biopsy needles.
FIGS. 16 to 18 show different views of the removable needle guide that can be attached to the probe's handle.
FIG. 19 illustrates a probe, in accordance with FIG. 15, with the needle guide of the preceding figures mounted thereon.
FIGS. 20 to 23 show a second embodiment of the probe's gripping elements, in the form of means of removable attachment to one finger of the hand.
FIGS. 24 to 26 show a variation of said elements for the probe's head, designed for gripping by means of the fingers of the hand according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 to 5, an intraoperative probe's transducer-carrying head (1) includes an elongated body, basically cylindrical in shape (2), housing the transducers (T), which are arranged in a row along the axis of said elongated body (2). The active surface of the transducers (T) is to be placed on a flattened area (102) extending in the direction of the axis of the housing body (2), while at the end opposite the insertion end, the basically cylindrical body (2) terminates in a connecting nonannular element (3). The cable (4) connecting the transducers (T) to processing and/or displaying devices exits in a basically coaxial direction the head side of the connecting end (3), said housing head (2) and connecting end (3) being at an angle relative to each other, while their axes lie in a plane that is basically perpendicular to the flattened area (102), so as to form an angle (α) of 45° between said axes, that is, between the plane parallel to said flattened area (102) of the transducer-carrying head (2) and the axis of the connecting end (3).
The shape of the flattened area (102), shown as perfectly flat in the illustration, can obviously be, as it is known to be, a curved shape generated around an axis perpendicular to the axis of the transducer-carrying head (2) and having a considerably larger radius.
The connecting end (3) is not round in shape; in particular, it has a square shape, the corner areas (103) between the faces being flattened or rounded.
With reference to FIGS. 6 to 10, the handle (5) consists of an elongated element (7) having a transversal U section or preferably a C-shaped section, that is, one that narrows on the open side or presents an angle greater than 180°, and also has a connecting seat (106) matching the connecting end (3) of the transducer-carrying head (1). Said connecting seat (106) has a basically square section and is obtained in a terminal portion (6) of the handle (5), said portion being at an angle relative to the axis of the handle (5) itself. The axis of the connecting seat (106) and the axis of said portion (7) of the handle (5) lie in the same plane and are at an angle relative to each other, so that the prolongation of the axis of portion (6) of the handle forms an angle (β) of approximately 30° with the axis of the connecting seat (106).
The handle (5) has a cable-holding groove (105) extending continuously from one end to the other of the handle itself and communicating with the connecting seat (106). The groove (105) and the connecting seat (106) itself are open along their whole length, with no break in continuity on the outside of the handle (5) with reference to the angle between the connecting terminal portion (6) and portion (7) of the handle, said opening making it possible to quickly and easily engage the connecting cable inside the handle (5) itself.
The groove (105) offers the advantage of having a cross section that basically matches the section of the cable, and by virtue of its C shape, with an angle greater than 180°, the opening for insertion of cable (4) is slightly narrower relative to the diameter of the cable (4) itself, so as to enable the insertion and removal of the cable by virtue of a slight elastic deformation of the same and/or the handle, but also effectively retaining it inside the groove (105).
FIGS. 11 to 14 illustrate four different examples of configurations of the probe of the present invention. These configurations can be obtained by simply changing the angle between the handle (5) and the transducer-carrying head (1). FIGS. 11 and 12 illustrate two configurations that are intermediate configurations between the L configuration shown in FIG. 13 and the J configuration shown in FIG. 14. These configurations basically correspond to the standard configurations of intraoperative probes currently available on the market. Obviously, with a connecting end (3) having a polygonal shape --for instance, hexagonal, octagonal or similar shape --and a connecting seat (106) with a matching section it is possible to obtain a larger number of intermediate probe configurations, differing from one another in respect of the different angle between the transducer-carrying head (2) and the handle (5).
The non-annular shape of the elements (3, 106) connecting the transducer-carrying head (2) to the handle (5) makes it possible to change the probe configuration quickly and conveniently, while assuring a remarkable stability of the connecting position of the transducer-carrying head (2) relative to the handle (5).
The probe of the present invention can be associated with additional removable and replaceable accessories, such as a needle guide (8) for a biopsy needle. In this particular case, as shown in FIGS. 15 to 19, the needle guide (8) can be directly and removably mounted, in a snap-on fashion, on the terminal portion (6) of the handle (5) forming the connecting seat (106) for the transducer-carrying head (2).
As shown in FIG. 15, the optimal probe configuration is the L configuration. The needle guide (8) consists of a guiding groove preferably U or V shaped and oriented in the direction of the axis of the terminal portion (6) where the connecting seat for the probe's head (2) is to be located. The guiding groove (108) is machined into a rib (208) projecting from a slide (308). Said slide (308) is equipped with snap-on elements for attaching to the outside of the connecting portion (6) of the handle (5) relative to the angle between said portion and part (7) of the handle, and is positioned over the opening of the groove (105) holding the cable (4).
The slide (308) has two lateral tabs (408), that is to say, it is basically shaped as an upside-down U. The free ends of said lateral tabs (408) have teeth (508) projecting toward the sides of the handle (5) that laterally delimit said cable-holding groove (105) and connecting seat (106), these being the sides where the mounting slots (206) are to be located. The mounting slots (206) for the slide (308) are parallel to the axis of the connecting portion and terminate as open slots on the outside of the same, that is, basically in the radius area between the grip (6) and the handle (5). Said slots are closed on the side of the transducer-carrying head (1) and determine the working position of the needle guide (8). With particular reference to FIG. 8, the invention provides for means of removable locking of the needle guide (8), hence of the slide (308), in its working position. In particular, in the middle portion of said slots there is to be a projection (306) forming a retaining tooth (406) designed to prevent detachment of the slide (308), the distance between said tooth and the closed head side of the corresponding slot (206) being basically equal to the length of the lugs (508) on said slide (308) designed to engage the grooves (106). On the open side, the end of said projection (306) has a lead-in surface, in the shape of an inclined plane (506), contributing to the progressive elastic spreading of the slide's tabs (408) that allows them to pass beyond said lug (306). The retaining tooth (406) is also slightly angled, but to a lesser degree than said lead-in surface, so as to allow detachment of the needle guide (8) only when a greater force is applied, thus preventing instances of accidental or undesired detachment.
According to an additional characteristic, slots (206) lie on a plane that is basically parallel to the opening of the cable-holding groove (105). This makes it possible to place the needle guide (108) in a position that is basically aligned with the middle plane perpendicular to the flattened area (102) of the body (2) housing the transducers (T). Preferably, on said plane the needle-guiding groove (308) sic! has a preset angle relative to the axis of the connecting seat (106) for the transducer-carrying head (1), so that it converges toward said axis in the direction of the head carrying the transducers (T), thus forming an angle of less than 45° with said flattened area.
This arrangement makes it possible to use the probe of the invention as a guiding and supporting structure for the needle, thus making it considerably easier to obtain tissue samples.
FIGS. 20 to 23 illustrate a second embodiment of the probe according to the invention. Here, the handle (5) is replaced by means of attachment to one finger of the hand. The probe's connecting seat (106) is designed in a manner similar to that previously described; however, instead of being located in a terminal portion of the handle (5), said connecting seat is designed in the shape of an open ring or bushing (6'). Said ring (6') is attached to an open thimble or ring (10) having a diameter basically corresponding to the diameter of the hand's fingers. Preferably, the open ring can be slightly spread by elastic deformation, so as to make possible its elastic coupling with the finger as well as its adaptation to the size of the same. In the embodiment illustrated in said figures, the open ring (6') with the connecting seat (106) for the transducer-carrying head and the open ring (10) for attachment to one finger are arranged with their axes basically parallel to each other and the respective openings diametrically opposite each other. Of course, this is not to be regarded as a restrictive arrangement, in that it is possible to provide for different reciprocal orientations and positions of the two rings (6', 10).
In the variation shown in FIGS. 24 to 26, in place of said open ring or thimble (10), the open ring (6') with the connecting seat for the transducer-carrying head (1) has a radial projection (11) in the shape of two opposing Cs forming two side-by-side, axially parallel grooves, as well as a widened area (111) on its free end. Said projection (11) is designed to make it possible to grasp the probe with two fingers of the hand, tightened around the radial projection (11) itself.
To allow a better grip of the probe the opposing grooves extend further toward the outside of the radius area between the open ring (6') and the connecting seat.
The two embodiments shown in FIGS. 20 to 26 can be attached to both the back and the palm of the hand.
Although they are not illustrated in detail, these two embodiments obviously may provide for removable means of attachment for accessories such as a needle guide (8) for biopsy needles, or the like. The probe may be constructed in a manner basically as described in the example shown in FIGS. 1 to 19, with the simple addition of specific dimensional and shape adaptations.
The invention obviously is not limited to the above descriptions and illustrations, but may be modified, especially in its construction, without thereby departing from its core principle as described above and claimed below.
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An intraoperative probe, specifically intended for direct-contact observations, includes a head for housing the transducers (T) and a portion of a handle or grip, as well as a cable for connecting the transducers (T) to processing and/or displaying devices. According to the invention, said portion of the handle or grip is separate from the transducer-carrying head, as said two parts are equipped with matching means of removable attachment. The invention also provides for a set of accessories that can be attached, individually or in various combinations, to said transducer-carrying head.
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TECHNICAL FIELD
The present invention relates in general to downhole operations and the production of electrical power within an oil producing wellbore. More specifically, the invention relates to a system for generating power from fluid flow through production tubing in a wellbore. Still more specifically, the invention relates to such a system using a magnetized rotation member that operates on principles similar to a Darrieus rotor and that is capable of generating a magnetic field to produce useable power.
BACKGROUND OF THE INVENTION
Downhole well applications, such as those used to extract crude oil from one or more production zones underneath the earth's surface, often require downhole power in order to operate components such as pressure and temperature sensors in the well. Current systems requiring downhole power include intelligent wells and permanent gauge installations where sensors or actuators are used in order to operate chokes and restrict fluid flow into a well at different levels for multiple zone production. Such systems are often necessary for control of pressure and flow from various zones.
Prior art downhole power generating systems include the use of an umbilical to power sensors and actuators from the surface. A typical umbilical comprises a protected electrical tethered line that can be used to deliver both power and data to the component as well as other downhole devices requiring power. In addition, wireless telemetry methods have proven useful for communications and general interfacing with such components and as a means of facilitating data transmission between the surface operator and the downhole device. Finally, batteries and battery packs can be used for short term power applications.
While such downhole power systems have proven useful, they do not meet the long term power needs of modern day production operations. For example, while the use of an umbilical is suitable for providing power and data communications to devices, the practical difficulties related to their installation and maintenance limits their long term usefulness. At the same time, umbilical systems can interfere with and obstruct the well, production tubing, and other down hole structures by restricting passage of tools and other components into the wellbore. The use of wireless telemetry with batteries has been contemplated, but such systems suffer from an inability to provide useful levels of power or sustain power over long periods of time.
Therefore, a long term downhole power solution that is suitable for use in a modem wellbore operation would provide numerous advantages.
SUMMARY OF THE INVENTION
The present invention provides a robust and efficient system for downhole power generation. The system utilizes a rotation member that operates on principles similar to those of a Darrieus rotor providing full access to the wellbore for passing tools into the wellbore. The airfoil is efficient, long lasting and can operate under a wide variety of flow conditions.
According to one embodiment, disclosed is a system for generating power from fluid flow in a wellbore. The system comprises a rotation member having a passageway through which objects may pass into the wellbore. A support mechanism is coupled to the rotation member inside the wellbore such that fluid flow through the passageway causes the rotation member to rotate. The rotation member is magnetized such that when it rotates it generates a magnetic field that produces usable power. Magnetic pickups are arranged about the rotation member within the magnetic flux lines of the magnetic field.
This system may further comprise a power conditioning unit and leads extending from magnetic pickups to a power conditioning unit such that a magnetic field generated by the rotational motion of the rotation member induces a current within the leads that is received by the power conditioning unit. The power conditioning unit may include a rectifier circuit to control the characteristics of the power generated by the rotation member.
The system may also comprise an output terminal coupled to the power conditioning unit and a lead extending from the output terminal to a component requiring power within the wellbore. The power conditioning unit may comprise one or more batteries, a capacitive bank, or a fuel cell adapted for storing the power generated by the rotation member. According to another embodiment, a starter rotor is provided comprising a pair of offset drag members which provide resistance to fluid flow within the wellbore and thereby facilitate rotation of the airfoil along the direction of fluid flow within the wellbore. A means of controlling the rotation of the rotation member may be provided, the means comprising a motor for starting and stopping the rotation of the rotation member and a control lead extending from outside the wellbore to the motor for allowing human operation of the motor from a point outside the wellbore.
Also disclosed is a power generating system for a oil producing operation having production tubing in a downhole wellbore. The system comprises a magnetized rotation member coupled to the wellbore within the production tubing, the rotation member having a passageway through which objects may be passed within the production tubing. A support mechanism couples the rotation member to the production tubing and allows the rotation of the rotation member within the production tubing. Magnetic pickups are predisposed about the rotation member within the wellbore and a power conditioning unit is provided with leads extending from the magnetic pickups to the power conditioning unit. The system operates such that fluid flow through the production tubing causes the rotation member to rotate and induce a magnetic field on the magnetic pickups such that electrical energy is produced and delivered to the power conditioning unit, the power conditioning unit capable of delivering usable power to any one of several electronic components within the wellbore.
The power generating system may further comprise a rectifier circuit for controlling the characteristics of the power stored in the power conditioning unit. A starter rotor may be used to assist the rotation of the rotation member, the starter rotor comprising a pair of offset and curved drag members which provide resistance to fluid flow within the wellbore and thereby facilitate rotation of the rotation member along the direction of fluid flow within the production tubing. In one embodiment, a DC-to-DC converter circuit is provided for delivering a stable DC voltage.
Also disclosed is a system for extracting fluids from a plurality of production zones intersected by a wellbore, the system including downhole power generation. The system comprises production tubing extending along a substantial length of the wellbore, the production tubing including at least one valve at each of the plurality of production zones with passages extending from the production zones to, each valve permitting the flow of fluid from the plurality of production zones into the production tubing via the valve. The system further comprises at least one magnetized rotation member coupled within the production tubing and predisposed to make contact with fluid flowing through the production tubing as a valve opens to permit fluid to flow from a production zone, the rotation member having a passageway through which objects may pass into the wellbore via the production tubing, wherein fluid flow through the passageway causes the rotation member to rotate thereby generating a magnetic field that produces useable power.
In one embodiment, the system further comprises a rotation member at each production zone intersected by the wellbore. The rotation members may be coupled together in series or parallel for high voltage and/or high current applications.
An advantage of the present invention is that it provides full access to the components in the wellbore and does not restrict the diameter of the production tubing, allowing tools to pass through the wellbore without clogging.
Another advantage of the present invention is that the rotation member provides a downhole power generation system with a relatively long life compared to umbilical systems and batteries.
Still another advantage of the present invention is the ability to provide downhole electrical power for long periods of time.
BRIEF DESCRIPTION OF THE DRAWINGS
The above advantages and specific embodiments will be understood from consideration of the following detailed description taken in conjunction with the appended drawings in which:
FIG. 1 is a figure illustrating a typical wellbore intersecting a plurality of production zones;
FIG. 2 shows a downhole operation with production tubing installed;
FIG. 3 illustrates a magnetized rotation member according to the present invention;
FIGS. 4A , 4 B, and 4 C illustrate use of the downhole power generating system of the present invention;
FIGS. 5A and 5B show two configuration of the rotation member according to the present invention;
FIG. 6 is a circuit schematic of a power generating system;
FIGS. 7A and 7B illustrate the positioning of an rotation member within production tubing;
FIG. 8 show the use of multiple rotation members for generating downhole power; and
FIG. 9 illustrates a downhole operation for extracting fluids such as crude oil from a plurality of production zones intersected by a wellbore having a system for downhole power generation according to the invention.
References in the detailed description correspond to like references in the figures unless otherwise indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a system for generating power within a wellbore and, more specifically, a downhole operation utilizing production tubing to remove fluids, such as crude oil, from one or more production zones underneath the earth's surface. With reference now to the figures, and in particular to FIG. 1 , therein is shown a typically downhole operation, denoted generally as 10 , in which the present invention may be utilized. In essence, the downhole operation 10 provides an excavation underneath the earth's surface 14 which is created using well known techniques in the energy industry. The operation 10 includes a wellbore 12 with wall 16 lined with casing 18 which has a layer of cement between the wellbore 12 and the casing 18 such that a hardened shell is formed along the interior of the wellbore 12 . For convenience, the singular and plural of a term (“passageway” and “passageways”, “zone” or “zones”, “sleeve” or “sleeves”, “packer” or “packers”, etc.) will be used interchangeable throughout and with the same reference number associated with both forms of the term.
FIG. 1 also shows a plurality of production zones 20 in which drilling operations are concentrated for the extraction of oil. Each production zone 20 is shown to have one or more passageways 22 leading from the production zone 20 to the interior of the wellbore 12 . The passageways 22 allow a flow of fluid from a production zone 20 into the wellbore 12 for extraction using methods well known to those of ordinary skill. Typically, the excavation of a wellbore, such as wellbore 12 , is a time consuming and costly operation and involves the drilling underneath the surface 14 to great depths. Therefore, it is expected that the wellbore 12 will be utilized for a relatively long period of time such that the operator can justify the investment in time and money.
Turning now to FIG. 2 , therein is shown an example downhole operation with production tubing 40 installed within the wellbore 12 . Essentially, the production tubing 40 provides the means of extracting fluids from the production zones 20 via a passageway extending underneath the surface 14 to above the earth. As shown, production tubing 40 consists of tube sections 42 A, 42 B, 42 C with end 44 , although the production tubing 40 may consist or more or less segments. The sections 42 A, 42 B, 42 C are joined together with sleeves 50 , each sleeve 50 being contained in an area defined by packers 60 , the use of which are well known in the industry. The physics governing the flow of fluids from a production zone 20 through the production tubing 40 is well known. As described below, the present invention utilizes the pressure regions defined by the packers 60 to provide the power generation functions of the present invention.
Seal 70 caps the production tubing 40 near the surface 14 of the downhole operation 10 . Each sleeve 50 has a corresponding valve 52 which can be operated via control lead 80 which provides a cable and means for passageway and closing valves 52 . In this way, the wellbore operator is able to control the flow of oil from any one of the available production zones 20 at any given time and at a desired level underneath surface 14 . Thus, the basic components of an oil drilling operation suitable for extracting oil from production zones 20 have been described.
Still referring to FIGS. 1 and 2 , the control lead 80 runs within an area known as an annulus 90 between the casing 16 and the production tubing 40 . The control lead 80 is operably coupled to sensors 92 which are positioned at different levels of the wellbore 12 about corresponding production zones 20 . In addition, the control lead 80 is operably coupled to chokes 94 which are used to operate corresponding valves 52 , and thereby restrict fluid flow into the wellbore 12 at different levels, permitting production out of multiple zones intersected by the production tubing 40 . As is well known in the art, by controlling fluid flow in this manner, the wellbore operator can have production from both a high pressure zone and a lower pressure zone. Moreover, by placing valves 52 at various levels where oil: producing formations are found, oil can be extracted using a singular piece of production tubing 40 , thereby optimizing the production operation for multiple zones at the same time and over a relatively long period of time.
Given that a typical wellbore operation, such as downhole operation 10 , is in use for years, it is often necessary to provide power to various components and devices within the wellbore 12 , but it may not be possible or desirable. Examples of such components include the sensors 92 , chokes 94 , and valves 52 used to control fluid flow. Prior art systems for power generation within the wellbore 12 include umbilical systems, batteries, and wireless telemetry, among others. The problems associated with such prior art power generation system are discussed above and relate generally to their inability to provide a long term source of power that does not interfere with production operations and allows the operator complete access to the wellbore 12 and production tubing 40 . For example, while the control lead 80 can be placed within an electrical tethered line that forms an umbilical into the passageway formed by the wellbore 12 , running such a line through the packers 60 , and through the entire length of the wellbore 12 can be a complicated and time-consuming task.
Moreover, while the data and control interface to the sensors 92 may be achieved using wireless telemetry, power must still be provided with a physical line coupled to the electrical components in the wellbore 12 . Apart from the difficulties of running a power line within the wellbore 12 , there is the added consideration that a physical line consumes space and therefore may interfere with access to the wellbore 12 and/or restrict the diameter of the wellbore 12 such that tools cannot pass into the wellbore 12 . At the same time, once the production tubing 40 is in place within the wellbore 12 , it may not be possible or desirable to remove the tubing 40 in order to replace sensors 92 or batteries needed to power them. Thus, what is needed is an efficient and robust solution for downhole power generation.
The present invention provides a way of powering components, such as sensors 92 , chokes 94 , and valves 52 within the wellbore 12 of a typical oil producing operation, such as downhole operation 10 . With the present invention, a downhole power generation system is provided that allows electrical power to be generated for a long period of time (5 to 10 years, for example) without disturbing the production tubing 40 or restricting access to the wellbore 12 . While the invention is described as useful in providing power to component in a well, such as wellbore 12 , it should be understood that the principles disclosed may have application in numerous production systems such as those where you may use more than one well or where you have multi-lateral wells.
Therefore, having described the components and general aspects of a typical downhole operation, reference is made to FIG. 3 , which illustrates the downhole wellbore power generation system, denoted generally as 100 , according to the invention. Power generation system 100 can be used to generate electrical power from fluid flow, such as crude oil, through production tubing 40 . As shown, the power generation system 100 includes a rotation member 110 with a passageway 112 through which objects may be passed. The passageway 112 facilitates the passage of tools into the wellbore 12 and, specifically, through the production tubing 40 .
The downhole power generation system 100 operates on similar principles as a Darrieus rotor. Fluid flow, indicated by arrow 102 , causes the rotation member 110 to rotate in the direction of arrow 104 which, in turn, generates a magnetic field which induces a current. The rotation member 110 comprises a rotation member or may be formed from two (2) arched and semi-circular arms that join at the first and second braces 170 , 172 which provide a support mechanism for the rotation member within the production tubing 40 . The braces 170 , 172 are but one form of a suitable support mechanism and those skilled in the art will readily recognize that other ways of supporting the rotation member 110 may be employed, such as a U-shaped hold, or single brace arm. Braces 170 , 172 provide free rotation of the rotation member 110 in the direction of arrow 104 . No specific means of rotation is required, although internal bearings (not shown) may be used to provide rotation as well as other designs as would be well understood by those of ordinary skill in the art.
In one embodiment, the rotation member 110 is made of a magnetic material. Alternatively, one or more magnets may also be attached to or otherwise connected to or within the rotation member 110 to create the desired field effects. In addition, one or more starter rotors 120 may be provided to assist the rotation member 110 during initial rotation after the onset of fluid flow. As shown, the power generation system 100 is contained within a section 130 of the production tubing 40 such as, for example, a sleeve 50 between two packers 60 .
It should be understood that the rotation member 110 can be used not only in production wells, but in injection wells such as those where water floods or steam floods are used, to produce power in those wells. Furthermore, the rotation member 110 can also be located in the annulus section of the well to be turned by lift gas that is injected down the annular which, as is well known in the art, is used to help lift the production fluids. Thus, any type of fluid moving through the well can be used to cause the rotation member to produce energy. Moreover, it will be readily appreciated that the rotation member 110 may be used in lateral wells as opposed to or in combination with the main well fork to keep the rest of the well bore clear and to provide easier access for getting tools in and out to all of the various laterals.
With reference to FIGS. 4A , 4 B, and 4 C, the rotational motion of the rotation member 110 within production tubing 40 is illustrated in more detail. FIG. 4A shows rotation member 110 partially blocking passageway 140 of section 130 of the production tubing. As fluid flows through passageway 140 , it is caught by the starter rotor 120 which is configured to translate the pressure of the fluid flow to the rotation member 110 . As seen more clearly in FIG. 4B , the starter rotor 120 is comprised of a pair of offset and curved drag members 121 , 122 which provide resistance to fluid flow within the wellbore 12 and thereby facilitate rotation of the rotation member 110 along the direction of fluid flow. Rotation member 110 is fixed about an axis of rotation X within the production tubing 40 such that it rotates from a position of partial obstruction ( FIG. 4A ) to no obstruction (FIG. 4 B). As shown, the axis of rotation X lies substantially perpendicular to the lengthwise axis Y of the wellbore 12 and production tubing 40 . Thus, full access to the wellbore 12 is maintained in at least one position of the rotation member 110 . Braces 170 , 172 provide rotation points and couple the rotation member 110 to section 130 .
Magnetic pickups 150 , 152 are positioned about the rotation member 110 and configured to translate the rotational motion of the rotation member 110 into electric energy in the form of current 160 . A magnetic field 180 is generated by the rotational action of the rotation member 110 which induces current 160 which traverses leads 154 and 156 extending from the magnetic pickups 150 , 152 to a load or to a power conditioning unit for storage and rectification. Preferably, the rotation of the rotation member 110 can be operator controlled from the outside such that the rotation member 110 can be maintained in the open position ( FIG. 4B ) permitting full access to the wellbore 12 and passage of tools. Since the rotation member 110 and other components are self-contained and can be made using high strength and long lasting materials, the power generation system 100 of the invention is robust and efficient.
With reference to FIGS. 5A and 5B , therein is shown the use of the downhole power generating system 100 of the present invention according to different configurations. Specifically, in FIG. 5A the rotation member 110 is located within a sleeve 50 of the production tubing 40 inside the wellbore 12 . Also, the magnetic pickup 150 extends from an area outside the sleeve 50 but within the distance of the magnetic flux lines of the field 180 produced by the rotation member 110 as it rotates. The magnetic pickup 150 has lead 154 extending through packer 60 , and coupled to power conditioning unit 200 where current induced on the magnetic pickup 150 is delivered. The power conditioning unit 200 can include power storage 202 and a rectifier circuit 204 that provide the ability to store and deliver a steady power value for use by a load, such as a sensor 92 within the wellbore 12 . Many forms of a suitable power storage 202 are envisioned including batteries, a capacitive bank, or fuel cell, as examples.
FIG. 5B shows the positioning of the rotation member 110 about tube section 42 A of the production tubing 40 . In this location, the rotation member 110 can be positioned anyplace where fluid flow is encountered thereby providing simple installation and the ability to place multiple rotation members 110 through the wellbore 12 . The use of multiple rotation members is illustrated in more detail in FIGS. 8 and 9 .
FIG. 6 is a circuit diagram of the power generating system of the present invention. Current I is generated by source 250 coupled to bridge circuit 252 . The bridge circuit 252 provides an interface between the power storage and the source 250 . As shown, the power storage is a capacitor 254 although other forms of storing a charge, such as a battery or fuel cell, may be used. A DC-to-DC converter circuit 260 is capable of rectifying the energy stored in capacitor 254 and delivering a steady amount of power to load 270 representing the electrical component inside the wellbore 12 to be powered.
FIGS. 7A and 7B illustrate the placement of the rotation member 110 within production tubing 40 . Line X intersects the rotation member 110 about its axis of rotation which is substantially perpendicular to the lengthwise axis Y of the wellbore 12 and production tubing 40 . FIG. 7B shows the cross-section of the rotation member about line X and in particular how the magnetic pickups 150 , 152 can be located to be adjacent to the rotation member 110 . The magnetic pickups 150 , 152 fit in the area between the casing 18 and the production tubing 40 known as the annulus 90 . Since no obstruction of the annulus 90 and the production tubing 40 takes place, full access to the wellbore 12 is provided. As shown, magnets 300 , 302 are attached to the rotation member 110 at a location near the magnetic pickups 150 , 152 .
Therefore, the present invention provides a power generating solution that may be configured according to the power needs of the downhole operation. For example, FIG. 8 shows the use of multiple rotation members 110 within the production tubing 40 of a wellbore, the rotation members 110 coupled to each other via leads 350 and 352 and extending to load 270 . Thus, rotation members 110 may L=be stacked in a series or parallel configuration for high voltage and/or high current applications as required by the load 270 . Moreover, the current generated by the rotation members 110 may be controlled via control lead 360 which couples one or more of the rotation members 110 within and allows operator control of the rotating action of the rotation members 110 from above the earth's surface. In this way, an operator can control when one or more of the rotation members 110 start and stop rotation as well as the speed of rotation which, in turn, controls the strength of the magnetic field and the amount of current induced in the magnetic pickups.
FIG. 8 shows each rotation member 110 having its own power conditioning unit 200 . It should be understood, however, that other ways of conditioning the power generated by the rotation members 110 may be employed. For example, a single power conditioning unit 200 may be sufficient to service all rotation members 110 according to the electrical power needs of the downhole operation. FIG. 9 shows the use of multiple rotation members 110 in place within the production tubing 40 of a downhole operation with control lead 360 extending through the production tubing 40 and to each rotation member 110 . An electromechanical motor 400 is provided and coupled to the control lead 360 for starting and stopping the rotating action of the rotation members 110 as well as speed of rotation. Activation of the rotation member 110 can be done achieved either by surface control or in response to sensors and control systems down hole. If done from the surface, it can be done by any of a number of methods all well known in the art, such as direct hard wire connection, hydraulic lines, acoustic telemetry, radio wave signals, pressure pulses or changes, etc. Likewise, the rotation member 110 may be turned ON and OFF in response to conditions down hole or as needed by equipment down hole, and may be activated or de-activated based upon those needs. For instance, if a high percentage of water is being detected coming in from one zone, the rotation member 110 can be activated by a down hole command and the control system can activate the rotation member to generate power to be used to shut the sliding sleeve and cut off the intruding water.
As shown, each rotation member 110 is associated with its own power conditioning unit 200 , although other configurations may be used. Also, each power conditioning unit 200 has an output terminal 380 leading to a component requiring power, in this case sensors 92 . Thus, the present invention provides a system for extracting crude oils, or other fluids, from a plurality of production zones 20 intersected by a wellbore 12 with downhole power generation.
It should be understood that the fluid moving past the rotation member 110 can come from a number of sources besides those discussed above. For example, the fluid may come from injected fluid, such as lift gas, or steam, or water used for flooding for secondary recovery purposes. The fluid movement can also be from fluid being moved from one zone in the well bore to another, as in the case where water comes out of a down hole oil water separator that's being transferred down and pumped into, or transferred to and pumped into a disposal zone at some other location within the well bore.
Moreover, while the rotation member 110 is shown located within the production tubing 40 , the rotation member 12 may be located in other locations of the well bore that allows fluid movement, i.e. where sufficient fluid movement occurs and where enough space is found to hold a rotation member 110 . For instance, the rotation member 110 may be located in the annular space where lift gas is being pumped in or possibly in the perforations or sliding sleeve ports where production fluid is entering the tubing 40 or annular areas.
Likewise, the invention can also be used in drilling systems to provide power down hole to operate the usual devices that are well known in the art in drilling operations such as, but not limited to, the directional drilling motors, logging equipment, data transmission equipment, etc. The rotation member 110 could be positioned in the general vicinity of the tools to minimize the transmission distance necessary, although other configurations may also be employed. Moreover, a downhole power generating system according to the present invention may work equally well with whatever type of drilling fluid is being used, including drilling muds and foams.
Therefore, the embodiments shown and described above are only exemplary. Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description together with details of the invention, the disclosure is illustrative only and changes may be made within the principles of the invention. It is therefore intended that such changes be part of the invention and within the scope of the following claims.
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A power generating system ( 100 ) for a downhole operation ( 10 ) having production tubing ( 40 ) in a wellbore ( 12 ) includes a magnetized rotation member ( 110 ) coupled to the wellbore ( 12 ) within the production tubing ( 40 ), the rotation member ( 110 ) having a passageway ( 112 ) through which objects, such as tools, may be passed within the production tubing ( 40 ). Support braces ( 170, 172 ) couple the rotation member ( 110 ) to the production tubing ( 40 ) and allow the rotation member ( 110 ) to rotate within the production tubing ( 40 ). Magnetic pickups ( 150, 152 ) are predisposed about the rotation member ( 110 ) within the wellbore ( 12 ) and a power conditioner ( 200 ) is provided to receive currents from the magnetic pickups ( 150, 152 ) for storage and future use. The rotation member ( 110 ) rotates due to the flow of fluid, such as crude oil, through the production tubing ( 40 ) which causes the rotation member ( 110 ) to rotate and induce a magnetic field on the magnetic pickups ( 150, 152 ) such that electrical energy is transmitted to the power conditioner ( 200 ), the power conditioner able to store, rectify, and deliver power to any one of several electronic components within the wellbore ( 12 ).
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FIELD OF THE INVENTION
The invention relates to an arrangement of draw-texturing machines for synthetic fibers, and more particularly to an arrangement of draw texturing machines that includes a drafting unit, a texturing unit, a relax unit and a winding unit.
BACKGOUND OF THE INVENTION
The processing of fibers such as synthetic fibers typically involves the use of various units such as a drafting unit, a texturing unit, a relax unit and a winding unit. As is known, such units are all provided in a parallel vertical arrangement, with the drafting unit, the texturing unit and the relax unit being located above the winding unit.
With the increasing yarn running speed up to 6000 meters/minute in the winding unit and the need to process and wind a multiplicity of threads simultaneously, the dimensions of the godets or rollers used in the drafting, texturing and relaxing units, have increased so much in diameter as well as length, that the threading of all these units is not without problems for the operating personnel. Further, the high thread running speed and the high temperatures of the godets present problems when such threading procedures are carried out manually since the threads must be guided through the suction jets by hand.
Difficult servicing leads in addition to faulty manipulations and potentially increased wastage during threading procedures of a product which is dear in itself, and also presents a certain amount of danger for the operating personnel.
SUMMARY OF THE INVENTION
For this reason, the task has been set of finding an arrangement of the individual units which addresses the foregoing concerns and facilitates machine operation.
The present invention provides a machine unit in which a drafting unit, a texturing unit and a relax unit are disposed above the winding unit and are arranged next to each other at least partially staggered and parallel to each other in a generally horizontal arrangement. The center line of at least one of the rollers of the drafting unit, the texturing unit and the relax unit each define an angle with respect to a reference plane which is larger than 0° and smaller than 90°, while the winding device defines an angle of 90° with respect to the reference plane. The winding units are arranged substantially in a row essentially parallel to each other.
It is advantageous when providing a plurality of machine units which each include a drafting unit, a texturing unit, a relax unit and a winder unit, to arrange the machine units as an entirety next to each other in a row. A further advantageous embodiment exists in that a generally centrally located, higher working position for the operator is provided, from which position all the details of the separate units of the machine unit can be serviced in detail when guiding the thread.
Advantages of the present invention lie in the fact that comfortable servicing is possible when "guiding" the thread through the aforementioned units during the running of the thread. Also, the entire course of the thread can be guided from a single position, through which there is a shorter guiding time for the threading. Further, because of the improved accessibility, fewer false threading manipulations occur and so less total wastage results.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Additional features and details of the invention will become more apparent from the detailed description of the invention set forth below considered in connection with the accompanying drawing figures in which like elements are designated by like reference numerals and wherein:
FIG. 1 is a front view of an arrangement of draw-texturing machines according to the invention, represented schematically in part; and
FIG. 2 is a top view of the arrangement shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a thread 1 originating from any prearranged unit, not represented, for example, a spinning tube, which in the course of the thread is guided primarily through an eyelet 2 before being guided through a suction device 3 and then through a separating knife 4. The thread is then guided with a predetermined number of windings over a pair of godets 5 and, after this, is guided with a predetermined number of windings over a pair of godets 6. The two pairs of godets 5, 6 together form a drafting unit.
After the pair of godets 6, the thread 1 is guided through a texturing unit 9, which can fundamentally be any known texturing unit, but in this case, however, is a so called "Rolltex"--texturing unit, which is shown and described in published European specification No. 0310890 A1. After the texturing unit 9, the texturing grafts, which are well known, arrive at a cooling drum 12 on which the filament, warmed and compressed in the texturing unit 9 to the aforementioned texturing grafts, is cooled.
After the cooling drum 12, the texturing graft is again released. That is, the thread is guided over the guide rollers 10, 11 which function as brakes, so that the grafts in the area between the guide rollers 11, 10 as well as before the following pair of godets 7, are again drafted to a thread in which the texturing, although in a stretched form here, has remained.
The pair of godets 7 form a relax unit, by means of which the textured threads are again warmed in a known way, in order to retain a texturing intensity of the predetermined kind.
Between the godets of the pair of godets 7, there is an intermingling jet 8 provided for the course of the thread, which, preferably after half of all the windings guided over the pair of godets 7, intermingles the textured thread in the known way. This intermingling jet can be, for example, an intermingling jet such as that which is sold under the trade name TEMCO.
After the relax unit 7, the textured and intermingled threads at the end of the course of the thread are guided into a winding device 13, in order to be wound on a winding mandrel 14 into a bobbin 15. The invention is not restricted to the use of the winding device shown. Rather, any winding device can be used.
According to the height of the arranged pairs of godets 5, 6, 7, a working position 16 (represented by dotted lines in FIG. 2) is provided which permits the operator, in the aforenamed threading process, to carry out the threading of the staggered arrangement of the rollers shown in plan view in FIG. 2. The working position 16 in the illustrated form is a stand which is elevated off the ground and on which the operator can stand.
FIG. 2 illustrates how the godets 5, 6, 7 forming the drafting unit and the relax unit are arranged relative to one another and to the working position 16. As seen with reference to FIG. 2, the center line 17 of one of the godets of each pair of godets 5, 6, 7 define an angle alpha (α) greater than 0° and smaller than 90°, preferably between 60° and 80°, with respect to a reference plane E. The reference plane E is a vertical plane positioned in spaced apart relation to the front portion of the bobbin 15. For the sake of simplicity, only the upper godet of each pair of godets is illustrated in FIG. 2. Also, in the illustrated arrangement, the longitudinal axis 17 of the upper godet of each pair of godets forms the angle α with respect to the reference plane E. FIG. 2 also depicts the positioning and orientation of the winding unit 13 and specifically illustrates the center line 18 of the winding mandrel 14 or of the bobbin 15 defining an angle δ with respect to the reference plane E. This angle δ is equal to or substantially equal to 90°.
As seen in FIG. 1, the draw unit, the texturing unit, the relax unit and the winding device 13 which together define a machine unit I are arranged next to each other in a partially staggered generally horizontal arrangement or row. As depicted in FIG. 2, the winding units 13 of adjacent machine units I are spaced from the imaginary reference plane E by a similar distance A.
The drafting unit and the relax unit are arranged in a way that facilitates access by an individual at the working position 16. In this regard, FIG. 2 illustrates that the longitudinal axis or center line of one of the godets of each of the drafting unit, the texturing unit 9 and the relax unit 7 are oriented at generally the same angle α with respect to the reference plane E. Further, from a plan view, the longitudinal axis or center line 17 of one of the godets of the pair of godets 5 and the longitudinal axis or center line 17 of one of the godets of the pair of godets 6 pass through the working position 16 as clearly seen in FIG. 2. From a three-dimensional standpoint, it can be said that the longitudinal axis or center line 17 of one of the godets of the godet pair 5 intersects a parallelepiped defined by an imaginary upward extension of the outer boundaries of the stand 16. Likewise, it can be said that the longitudinal axis or center line 17 of one of the godets of the godet pair 6 also intersects such a parallelepiped.
The horizontal arrangement of the godet pairs 5, 6, 7 is clearly shown in FIG. 2 where it can be seen that the longitudinal axis 17 of one of the godets of each pair is horizontally spaced from the longitudinal axis 17 of the one godet of the adjacent godet pair.
As a result of the foregoing arrangement, an operator standing on the stand 16, which can possess a length of about one meter in the direction parallel to the reference plane E and a width approximately one-half the length, can easily reach all of the units forming the machine unit, thus greatly improving the ease with which the units can be serviced. As can be seen, the drafting unit 5, 6, the texturing unit 9 and the relax unit 7, are arranged so that the threads 1 extending from the godets 5 of the drafting unit to the godets 7 of the relax unit 7 traverse a space located directly above the working stand 16.
Preferably, the relax unit 7 is positioned vertically above the winding unit so that the textured and intermingled threads from the relax unit are able to extend substantially straight downwardly to the winding unit 13 without significant deviation. In addition, although the foregoing description in conjunction with the illustration in FIG. 2 refers to the longitudinal axis 17 of the upper godet of the respective godet pair, it is to be understood that the longitudinal axis 17 could also be the longitudinal axis of the lower godet of each respective godet pair. Also, the longitudinal axis 17 could refer to what would constitute a median longitudinal axis defined by the median of the longitudinal axes of the godets forming each godet pair.
The principles, preferred embodiments and modes of operation and the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby.
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A machine unit through which a thread is guided includes a drafting unit comprised of double godets, a texturing unit, a relax unit comprising double rollers, and a winding device. The drafting unit and the relax unit are arranged at an angle of less than 90° to a reference plane, while the winding device is arranged at an angle (δ) of essentially 90° to the reference plane. Furthermore, an operator's working position is provided, from which the aforementioned arrangement of the drafting unit and relax unit relative to the winding device is accessible.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/145,027, filed Jan. 15, 2009, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The disclosure of the present application is in the field of medicinal chemistry. In particular, this application discloses a class of novel compounds that allosterically modulate α7 nicotinic acetylcholine receptor (α7nAChR) and may be used to treat disorders amenable to modulation of the α7nAChR.
[0003] α7 nAChRs belong to the ligand-gated ion channel superfamily of Cys-loop receptors. The Cys-loop superfamily includes muscle and neuronal nAChRs, 5-hydroxytryptamine type 3 (5HT 3 ), γ-aminobutyric acid A (GABA A ), GABA C and glycine receptors. α7 nAChRs are ion channels that recognize acetylcholine and choline as the endogenous orthosteric ligand and also bind nicotine at the orthosteric site. α7 nAChRs contain 5 orthosteric receptor sites per receptor. Agonist binding to the orthosteric site effects functional states of the receptor depending on the concentration and kinetics of agonist application. Four functional states have been described for α7 nAChRs: one open and three closed states (resting, fast-onset desensitized, slow-onset desensitized). Unlike agonists, allosteric modulators of α7 nAChRs do not bind to the orthosteric site, and cannot affect the functional state of the ion channel by themselves. An allosteric modulator of α7 nAChRs requires the presence of an agonist to open the channel. Positive allosteric modulators lower the energy barrier between resting and active states of the protein and increase the agonist-evoked response; negative allosteric modulators increase this energy barrier and cause a reduction in the agonist response. In the brain, activation of neuronal α7 nAChRs mediates fast synaptic transmission and controls synaptic transmission by the major inhibitory and excitatory neurotransmitters, GABA and glutamate.
[0004] α7 nAChRs mediate the predominant nicotinic current in hippocampal neurons. α7 nAChR was initially identified from a chick brain library as an α-bungarotoxin binding protein that exhibits ˜40% sequence homology to other nAChRs. α7 nAChRs share similar features of other neuronal and muscle nAChRs such as a pentameric Cys-loop receptor structure and M2 segment of each subunit lining of the channel pore, however α7 nAChRs exhibits a homopentameric structure when reconstituted in Xenopus oocytes, a characteristic shared only with α8 and α9 nAChRs. Heterologously expressed homomeric α7 nAChRs in Xenopus oocytes are inactivated by α-bungarotoxin with high affinity, whereas other nAChRs are not. α7 nAChRs have also been pharmacologically identified by distinct types of whole cell currents elicited by nicotinic agonists in hippocampal neurons. When exposed to various nicotinic agonists, whole cell recordings from cultured hippocampal neurons show, in general, type IA currents that have a very brief open time, high conductance, very high Ca ++ permeability, decay rapidly, and are sensitive to blockade by methyllycaconitine (MLA) and α-bungarotoxin. The properties of these nicotinic currents in hippocampal neurons correspond to the currents mediated by α7 nAChRs expressed in oocytes.
SUMMARY OF THE INVENTION
[0005] Briefly, this invention is generally directed to allosteric modulators of α7nAChR, as well as to methods for their preparation and use, and to pharmaceutical compositions containing the same. More specifically, the allosteric α7nAChR modulators of this invention are compounds represented by the general structure:
[0000]
[0000] including pharmaceutically acceptable salts, esters, solvates, and prodrugs thereof,
wherein R 2 , R 3 , R 4 , R 5 , R 7 , R 8 , and X are as defined below.
[0006] Further, the present invention is directed to 3 H, 11 C, 18 F, 35 S, 36 Cl, 14 C and 125 I radiolabeled compounds of Formula I and their use as radioligands for their binding site on the α7nAChR complex.
[0007] This invention also is directed to methods of treating disorders responsive to enhancement of acetylcholine action on α7 nAChRs in a mammal by administering an effective amount of a compound of Formula I as described herein. Compounds of the present invention may be used to treat a variety of disorders, including of the central nervous system (CNS). Disorders of the CNS include but are not limited to neurodegenerative diseases, senile dementias, schizophrenia, Alzheimer's disease, learning deficit, cognition deficit, memory loss, Lewy Body dementia, attention-deficit disorder, attention deficit hyperactivity disorder, anxiety, mania, manic depression, Parkinson's disease, Huntington's disease, amyotrophic lateral sclerosis, brain inflammation and Tourette's syndrome. In addition, compounds of the present invention may be used to treat pain, inflammation, septic shock, ulcerative colitis and irritable bowel syndrome.
[0008] The present invention also is directed to pharmaceutical formulations which include a compound of the present invention. Such formulations contain a therapeutically effective amount of a compound of Formula I and one or more pharmaceutically acceptable carriers or diluents.
[0009] Additional embodiments and advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The embodiments and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
[0010] 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, as claimed.
DETAILED DESCRIPTION
[0011] In one aspect, the present invention is directed to a compound of Formula I:
[0000]
[0000] or a pharmaceutically acceptable salt, ester, prodrug or solvate thereof, wherein:
[0012] X is O, S or N—R 1 ;
[0013] R 1 is hydrogen, C 1-8 alkyl, C 2-8 alkenyl, C 2-8 alkynyl, or C 1-8 haloalkyl, wherein each of said alkyl, alkenyl, alkynyl, and haloalkyl is optionally substituted with one or more R 9 ; or
[0014] R 1 is aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0015] R 2 is hydrogen, halogen, nitrile, nitro or C(═O)R 9 ; or
[0016] R 2 is C 1-8 alkyl, C 2-8 alkenyl, C 2-8 alkynyl, or C 1-8 haloalkyl, wherein each of said alkyl, alkenyl, alkynyl, and haloalkyl is optionally substituted with one or more R 9 ; or
[0017] R 2 is aryl, carbon-attached heteroaryl, cycloalkyl, cycloalkenyl, carbon-attached heterocycloalkyl or carbon-attached heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0018] R 3 is aryl, heteroaryl, heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0019] R 4 is hydrogen, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, or C 1-8 haloalkyl, wherein each of said alkyl, alkenyl, alkynyl, and haloalkyl is optionally substituted with one or more R 9 ; or
[0020] R 4 is aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl or heterocycloalkenyl, wherein heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0021] R 5 is hydrogen, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, C 1-6 haloalkyl, —C(═O)R 9 , —S(═O) 0-2 R 9 , —S(═O) 0-2 -A-R 9 or -A-C(═O)R 9 , wherein each of said alkyl, alkenyl, alkynyl, and haloalkyl is optionally substituted with one or more R 9 ; or
[0022] R 5 is aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ; or
[0023] R 4 and R 5 taken together with the nitrogen to which they are attached form a heteroaryl, a heterocycloalkyl or a heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said heteroaryl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0024] each of R 7 and R 8 is independently hydrogen, C 1-8 alkyl, C 1-8 alkoxy, C 2-8 alkenyl, C 2-8 alkynyl, C 1-8 haloalkyl, or C 1-8 haloalkoxy; wherein each of said alkyl, alkenyl, alkynyl, haloalkyl, and haloalkoxy is optionally substituted with one or more R 9 ; or
[0025] each of R 7 and R 8 is independently halogen, nitrile, nitro, hydroxyl, —C(═O)R 9 , —S(═O) 0-2 R 9 , —NR 4 R 5 , —S(═O) 0-2 -A-R 9 or -A-C(═O)R 9 ; or
[0026] each of R 7 and R 8 is independently aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted with 1-5 R 10 ; or
[0027] R 9 is hydroxyl, C 1-6 alkoxy, C 1-8 haloalkoxy, C 3-6 cycloalkoxy or NR 11 R 12 ; or
[0028] R 9 is aryl, heteroaryl, cycloalkyl, or cycloalkenyl, wherein each of said aryl, heteroaryl, cycloalkyl and cycloalkenyl are optionally substituted with 1-5 R 10 ; or
[0029] R 9 is heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O), wherein each of said heterocycloalkyl and said heterocycloalkenyl is optionally substituted with 1-5 R 10 ;
[0030] R 10 is nitro, nitrile, hydroxyl, halogen, C 1-6 acyl, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 1-6 haloalkoxy, cycloalkoxy, cycloalkyloxy, aryl, heteroaryl, —NR 11 R 12 , —C(═O)OR 11 , —C(═O)NHR 11 , —NHC(═O)R 13 , —NHS(═O) 2 R 13 , —S(═O) 0-2 R 13 , —S(═O) 2 NHR 11 , cycloalkyl, cycloalkenyl, heterocycloalkyl or heterocycloalkenyl, wherein said heterocycloalkyl is optionally fused with a phenyl or a 5-6 membered heteroaryl having 1-3 heteroatoms, wherein one or more of the carbon atoms in said heterocycloalkyl or heterocycloalkenyl may be oxidized to C(═O); wherein each of said alkyl, alkenyl, alkynyl, haloalkyl, alkoxy, haloalkoxy, cycloalkoxy, cycloalkyloxy, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, and heterocycloalkenyl is optionally substituted;
[0031] each of R 11 and R 12 is independently hydrogen, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, C 1-6 haloalkyl, cycloalkyl or cycloalkenyl; wherein each of said alkyl, alkenyl, alkynyl, haloalkyl, cycloalkyl and cycloalkenyl is optionally substituted with one or more R 9 ;
[0032] R 13 is C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, C 1-6 haloalkyl, C 3-6 cycloalkyl or C 4-6 cycloalkenyl; wherein each of said alkyl, alkenyl, alkynyl, haloalkyl, cycloalkyl and cycloalkenyl is optionally substituted; and
[0033] A is C 1-4 alkyl, C 2-8 alkenyl or C 1-8 haloalkyl.
[0034] In one embodiment X is NR 1 . In another embodiment X is O. In another embodiment X is S.
[0035] In one embodiment, R 1 is hydrogen, C 1-6 alkyl, C 1-6 haloalkyl or C 1-6 cycloalkyl, wherein each of said C 1-6 alkyl and C 1-6 haloalkyl is optionally substituted with one or more R 9 and said C 1-6 cycloalkyl is optionally substituted with 1-5 R 10 . In one such embodiment, R 1 is hydrogen or C 1-6 alkyl. In one embodiment, R 1 is hydrogen. In another embodiment, R 1 is methyl, ethyl or cycloporpyl.
[0036] In one embodiment, R 2 is hydrogen, C 1-6 alkyl, C 1-6 haloalkyl or C 1-6 cycloalkyl, wherein each of said C 1-6 alkyl and C 1-6 haloalkyl is optionally substituted with one or more R 9 and said C 1-6 cycloalkyl is optionally substituted with 1-5 R 10 . In one such embodiment, R 2 is hydrogen or C 1-6 alkyl. In one embodiment, R 2 is hydrogen. In another embodiment, R 2 is methyl or ethyl.
[0037] In one embodiment, R 3 is aryl or heteroaryl, wherein each of said aryl and heteroaryl is optionally substituted with 1-5 R 10 . In one such embodiment, R 3 is aryl substituted with halogen, C 1-6 alkyl or C 1-6 alkoxy.
[0038] In one embodiment R 4 is hydrogen.
[0039] In one embodiment R 5 is C 1-6 alkyl optionally substituted with one or more R 9 . In one such embodiment R 9 is aryl or cycloalkyl. In one such embodiment R 9 is aryl.
[0040] In one embodiment each of R 7 and R 8 is independently hydrogen, C 1-6 alkyl, C 1-6 haloalkyl or C 1-6 cycloalkyl. In one embodiment, each of R 7 and R 8 is independently hydrogen.
[0041] In one embodiment, R 9 is aryl, heteroaryl or cycloalkyl. In one such embodiment, R 9 is aryl. In another such embodiment, R 9 is heteroaryl. In another such embodiment, R 9 is cycloalkyl.
[0042] In one embodiment, R 10 is halogen, C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy or cycloalkyloxy. In one such embodiment, R 10 is halogen or C 1-6 alkyl. In one embodiment, R 10 is halogen. In another embodiment, R 10 is C 1-6 alkyl.
DEFINITIONS
[0043] Unless specifically noted otherwise herein, the definitions of the terms used are standard definitions used in the art of organic synthesis and pharmaceutical sciences.
[0044] The term “halogen” as used herein refers to a halogen radical selected from fluoro, chloro, bromo and iodo.
[0045] The term “nitrile” refers to —C≡N.
[0046] The term “nitro” refers to —NO 2 .
[0047] The term “alkyl” refers to a saturated aliphatic hydrocarbon radical. “Alkyl” refers to both branched and unbranched alkyl groups. Examples of “alkyl” include alkyl groups that are straight chain alkyl groups containing from one to ten carbon atoms and branched alkyl groups containing from three to ten carbon atoms. “Alkyl” includes but is not limited to straight chain alkyl groups containing from one to six carbon atoms and branched alkyl groups containing from three to six carbon atoms. This term is exemplified by groups such as methyl, ethyl, n-propyl, 1-methylethyl(isopropyl), 1,1-dimethylethyl(tert-butyl), and the like. It may be abbreviated “Alk”. It should be understood that any combination term using an “alk” or “alkyl” prefix refers to analogs according to the above definition of “alkyl”. For example, terms such as “alkoxy”, “alkylthio”, “alkylamino” refer to alkyl groups linked to a second group via an oxygen, sulfur, or nitrogen atom, respectively.
[0048] The term “haloalkyl” refers to an alkyl group in which one or more hydrogen atoms are replaced with halogen atoms. This term includes but is not limited to groups such as trifluromethyl. In one embodiment the haloalkyl groups are alkyl groups substituted with one or more fluoro or chloro. The term “haloalkoxy” refers to haloalkyl groups linked to a second group via an oxygen atom.
[0049] The term “alkenyl” refers to a mono or polyunsaturated aliphatic hydrocarbon radical. The mono or polyunsaturated aliphatic hydrocarbon radical contains at least one carbon-carbon double bond. “Alkenyl” refers to both branched and unbranched alkenyl groups, each optionally partially or fully halogenated. Examples of “alkenyl” include alkenyl groups that are straight chain alkenyl groups containing from two to ten carbon atoms and branched alkenyl groups containing from three to ten carbon atoms. Other examples include alkenyl groups which are straight chain alkenyl groups containing from two to six carbon atoms and branched alkenyl groups containing from three to six carbon atoms. Alkenyl groups include but are not limited to ethenyl, propenyl, n-butenyl, isobutenyl, 3-methylbut-2-enyl, n-pentenyl, heptenyl, octenyl, decenyl, and the like.
[0050] The term “alkynyl” refers to a mono or polyunsaturated aliphatic hydrocarbon radical. The mono or polyunsaturated aliphatic hydrocarbon radical contains at least one carbon-carbon triple bond. “Alkynyl” refers to both branched and unbranched alkynyl groups, each optionally partially or fully halogenated. Examples of “alkynyl” include alkynyl groups that are straight chain alkynyl groups containing from two to ten carbon atoms and branched alkynyl groups containing from four to ten carbon atoms. Other examples include alkynyl groups that are straight chain alkynyl groups containing from two to six carbon atoms and branched alkynyl groups containing from four to six carbon atoms. This term is exemplified by groups such as ethynyl, propynyl, octynyl, and the like.
[0051] The term “cycloalkyl” refers to the mono- or polycyclic analogs of an alkyl group, as defined above. Unless otherwise specified, the cycloalkyl ring may be attached at any carbon atom that results in a stable structure and, if substituted, may be substituted at any suitable carbon atom which results in a stable structure. Examples of cycloalkyl groups are saturated cycloalkyl groups containing from three to ten carbon atoms. Other examples include cycloalkyl groups containing three to eight carbon atoms or three to six carbon atoms. Exemplary cycloalkyl groups include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cyclooctyl, cyclononyl, cyclodecyl, norbornane, adamantyl, and the like.
[0052] The term “cycloalkenyl” refers to the mono- or polycyclic analogs of an alkenyl group, as defined above. Unless otherwise specified, the cycloalkenyl ring may be attached at any carbon atom that results in a stable structure and, if substituted, may be substituted at any suitable carbon atom which results in a stable structure. Examples of cycloalkenyl groups are cycloalkenyl groups containing from four to ten carbon atoms. Other examples include cycloalkenyl groups containing four to eight carbon atoms or four to six carbon atoms. Exemplary cycloalkenyl groups include but are not limited to cyclobutenyl, cyclopentenyl, cyclohexenyl, norbornene, and the like.
[0053] The term “heterocycloalkyl” refers to the mono- or polycyclic structures of “cycloalkyl” where one or more of the carbon atoms are replaced by one or more atoms independently selected from nitrogen, oxygen, or sulfur atoms. Any nitrogen atom maybe optionally oxidized or quaternized, and any sulfur atom maybe optionally oxidized. Generally, the heteroatoms may be selected from the group consisting of N, S, S═O, S(═O) 2 , and O. Unless otherwise specified, the heterocycloalkyl ring may be attached at any carbon atom or heteroatom that results in a stable structure and, if substituted, may be substituted at any suitable carbon atom or heteroatom which results in a stable structure. Examples of heterocycloalkyl groups are saturated heterocycloalkyl groups containing from two to nine carbon atoms and one to four heteroatoms. Generally, 5-7 membered heterocycloalkyl groups contain 3-6 carbon atoms and 1-2 heteroatoms independently selected from the group consisting of N, S, S═O, S(═O) 2 , and O. Examples of heterocycloalkyl groups include but are not limited to morpholino, pyrazino, tetrahydrofurano, and the like. “Carbon-attached heterocycloalkyl” refers to a heterocycloalkyl group which is bound via a constituent carbon atom. A heterocycloalkyl that is fused with a phenyl can include, but is not limited to, the following:
[0000]
[0000] A heterocycloalkyl that is fused with a 5-6 membered heteroaryl can include, but is not limited to, the following:
[0000]
[0054] The term “heterocycloalkenyl” refers to the mono- or polycyclic structures of “cycloalkenyl” where one or more of the carbon atoms are replaced by one or more atoms independently chosen from nitrogen, oxygen, or sulfur atoms. Any nitrogen atom maybe optionally oxidized or quaternized, and any sulfur atom maybe optionally oxidized. Unless otherwise specified, the heterocycloalkenyl ring may be attached at any carbon atom or heteroatom that results in a stable structure and, if substituted, may be substituted at any suitable carbon atom or heteroatom which results in a stable structure. Examples of heterocycloalkenyl groups are saturated heterocycloalkenyl groups containing from two to nine carbon atoms and one to four heteroatoms. Generally, 5-7 membered heterocycloalkenyl groups contain 3-6 carbon atoms and 1-2 heteroatoms independently selected from the group consisting of N, S, S═O, S(═O) 2 , and O. Examples of heterocycloalkenyl groups include but are not limited to dihydropyran, dihydrofuran, and the like. “Carbon-attached heterocycloalkenyl” refers to a heterocycloalkenyl group which is bound via a constituent carbon atom.
[0055] The term “cycloalkyloxy” refers to a monovalent radical of the formula —O-cycloalkyl, i.e., a cycloalkyl group linked to a second group via an oxygen atom, wherein the cycloalkyl group is as defined above including optionally substituted cycloalkyl groups as also defined herein.
[0056] The term “acyl” refers to a monovalent radical of the formula —C(═O)-alkyl and —C(═O)-cycloalkyl, i.e., an alkyl or cycloalkyl group linked to a second group via carbonyl group C(═O), wherein said alkyl maybe further substituted with cycloalkyl, aryl, or heteroaryl. Examples of acyl groups include —C(═O)Me (acetyl), —C(═O)CH 2 -cyclopropyl(cyclopropylacetyl), —C(═O)CH 2 Ph (phenylacetyl), and the like.
[0057] The term “aryl” refers to 6-10 membered mono- or polycyclic aromatic carbocycles, for example, phenyl and naphthyl. Unless otherwise specified, the aryl ring may be attached at any carbon atom that results in a stable structure and, if substituted, may be substituted at any suitable carbon atom which results in a stable structure. The term “aryl” refers to non-substituted aryls and aryls optionally substituted with one or more substituents. Aryl maybe abbreviated “Ar”. It should be understood that any combination term using an “ar” or “aryl” prefix refers to analogs according to the above definition of “aryl”. For example, terms such as “aryloxy”, “arylthio”, and “arylamino” refer to aryl groups linked to a second group via an oxygen, sulfur, or nitrogen atom, respectively.
[0058] The term “heteroaryl” refers to a stable 5-8 membered monocyclic or 8-11 membered bicyclic aromatic heterocycle radical. In one embodiment the monocyclic groups are 5 or 6 membered. Each heteroaryl contains 1-10 carbon atoms and from 1 to 5 heteroatoms independently chosen from nitrogen, oxygen and sulfur, wherein any sulfur heteroatom may optionally be oxidized and any nitrogen heteroatom may optionally be oxidized or quaternized. Unless otherwise specified, the heteroaryl ring may be attached at any suitable heteroatom or carbon atom that results in a stable structure and, if substituted, may be substituted at any suitable heteroatom or carbon atom which results in a stable structure. The term “heteroaryl” includes heteroaryl groups that are non-substituted or those optionally substituted. Generally, heteroaryl groups containing 2-9 carbon atoms and 1-4 heteroatoms independently selected from the group N, S, S═O, S(═O) 2 , and O. Examples of “heteroaryl” include but are not limited to radicals such as furanyl, thienyl, pyrrolyl, oxazolyl, thiazolyl, imidazolyl, pyrazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, triazolyl, tetrazolyl, thiadiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, indolizinyl, indolyl, isoindolyl, benzofuranyl, benzothienyl, indazolyl, benzimidazolyl, benzothiazolyl, benzoxazolyl, benzisoxazolyl, benzisothiazolyl, purinyl, quinolizinyl, quinolinyl, isoquinolinyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, naphthyridinyl, pteridinyl, carbazolyl, acridinyl, phenazinyl, phenothiazinyl and phenoxazinyl. Terms such as “heteroaryloxy”, “heteroarylthio”, “heteroarylamino” refer to heteroaryl groups linked to a second group via an oxygen, sulfur, or nitrogen atom, respectively.
[0059] Each of the groups described herein, including alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, cycloalkyloxy, acyl, aryl, heteroaryl, all are optionally substituted.
[0060] The terms “optional” or “optionally” mean that the subsequently described event or circumstances may or may not occur, and that the description includes instances where the event or circumstance occurs and instances in which it does not. For example, “optionally substituted aryl” means that the aryl radical may or may not be substituted and that the description includes both substituted aryl radicals and aryl radicals having no substitution. Exemplary optional substituents include one or more of the following groups: halogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 6 haloalkyl C 2 -C 6 alkenyl, C 4 -C 6 cycloalkenyl, C 2 -C 6 alkynyl, nitro, nitrile, cyano, hydroxyl, C 1 -C 6 alkoxy, C 1 -C 6 haloalkoxy, C 3 -C 6 cycloalkoxy, amino, C 1 -C 6 alkylamino (for example, —NHMe- or —N(Me) 2 ), C 1 -C 6 acyl, thiol, alkylthio, and carboxylic acid. Additional optional substituents include aryl, heteroaryl, heterocycloalkyl and heterocycloalkenyl. Such substituents can further be substituted with optionally selected groups to foam a stable structure.
[0061] As used herein “solvate” refers to a complex of variable stoichiometry formed by a solute (e.g. a compound of formula (I) or a salt, ester or prodrug thereof) and a solvent. Such solvents for the purpose of the invention may not interfere with the biological activity of the solute. Examples of suitable solvents include water, methanol, ethanol and acetic acid. Generally the solvent used is a pharmaceutically acceptable solvent. Examples of suitable pharmaceutically acceptable solvents include water, ethanol and acetic acid. Generally the solvent used is water.
[0062] “Isomers” mean any compound with an identical molecular formula but having a difference in the nature or sequence of bonding or arrangement of the atoms in space. Examples of such isomers include, for example, E and Z isomers of double bonds, enantiomers, and diastereomers. Compounds of the present invention depicting a bond with a straight line or “squiggly line” representation that is attached to a double bond, unless specifically noted otherwise, is intended to encompass a single isomer and/or both isomers of the double bond as shown below mean any compound with an identical molecular formula but having a difference in the nature or sequence of bonding or arrangement of the atoms in space.
[0063] As used herein “allosteric modulator” of α7 nAChR refers to a compound that that binds allosterically to α7 nAChR, thereby increasing (positive allosteric modulator) or decreasing (negative allosteric modulator) the agonist-evoked response.
[0064] As used herein a “disorder amenable to modulation of α7nAChR” refers to a disorder associated with α7nAChR dysfunction and/or a disorder in which α7nACh receptors are involved. Such disorders include, but are not limited to neurodegenerative diseases, senile dementias, schizophrenia, Alzheimer's disease, learning deficits, cognition deficits memory loss, Lewy Body dementia, attention-deficit disorder, attention deficit hyperactivity disorder, anxiety, mania, manic depression, Parkinson's disease, Huntington's disease, amyotrophic lateral sclerosis, brain inflammation, Tourette's syndrome, pain, inflammation, septic shock, ulcerative colitis and irritable bowel syndrome.
[0065] As used herein “a cognitive disorder related to learning or memory” refers to a mental disorder that affects cognitive functions, such as memory, learning, perception, problem-solving, conceptualization, language, reading comprehension, linguistic comprehension, verbal comprehension, math comprehension, visual comprehension and attention. Cognitive disorders related to learning or memory include, but are not limited to, mild cognitive impairment, age related cognitive decline, senile dementia and Alzheimer's disease.
Formulations
[0066] Compounds of the invention may be administered orally in a total daily dose of about 0.01 mg/kg/dose to about 100 mg/kg/dose, typically from about 0.1 mg/kg/dose to about 10 mg/kg/dose. The use of time-release preparations to control the rate of release of the active ingredient may be employed. The dose may be administered in as many divided doses as is convenient. When other methods are used (e.g. intravenous administration), compounds may be administered at a rate from 0.05 to 10 mg/kg/hour, typically from 0.1 to 1 mg/kg/hour. Such rates are easily maintained when these compounds are intravenously administered as discussed below.
[0067] For the purposes of this invention, the compounds may be administered by a variety of means including orally, parenterally, by inhalation spray, topically, or rectally in formulations containing pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used here includes subcutaneous, intravenous, intramuscular, and intraarterial injections with a variety of infusion techniques. Intraarterial and intravenous injection as used herein includes administration through catheters. Oral administration is generally employed.
[0068] Pharmaceutical compositions containing the active ingredient may be in any form suitable for the intended method of administration. When used for oral use for example, tablets, troches, lozenges, aqueous or oil suspensions, dispersible powders or granules, emulsions, hard or soft capsules, syrups or elixirs may be prepared. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents including sweetening agents, flavoring agents, coloring agents and preserving agents, in order to provide a palatable preparation. Tablets containing the active ingredient in admixture with non-toxic pharmaceutically acceptable excipient which are suitable for manufacture of tablets are acceptable. These excipients may be, for example, inert diluents, such as calcium or sodium carbonate, lactose, calcium or sodium phosphate; granulating and disintegrating agents, such as maize starch, or alginic acid; binding agents, such as starch, gelatin or acacia; and lubricating agents, such as magnesium stearate, stearic acid or talc. Tablets may be uncoated or may be coated by known techniques including microencapsulation to delay disintegration and adsorption 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 alone or with a wax maybe employed.
[0069] Formulations for oral use may be also presented as hard gelatin capsules where the active ingredient is mixed with an inert solid diluent, for example calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, such as peanut oil, liquid paraffin or olive oil.
[0070] Aqueous suspensions of the invention contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients include a suspending agent, such as sodium carboxymethylcellulose, methylcellulose, hydroxypropyl methylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia, and dispersing or wetting agents such as a naturally occurring phosphatide (e.g., lecithin), a condensation product of an alkylene oxide with a fatty acid (e.g., polyoxyethylene stearate), a condensation product of ethylene oxide with a long chain aliphatic alcohol (e.g., heptadecaethyleneoxycetanol), a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol anhydride (e.g., polyoxyethylene sorbitan monooleate). The aqueous suspension may also contain one or more preservatives such as ethyl or n-propyl p-hydroxy-benzoate, one or more coloring agents, one or more flavoring agents and one or more sweetening agents, such as sucrose or saccharin.
[0071] Oil suspensions may be formulated by suspending the active ingredient in a vegetable oil, such as arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oral suspensions may contain a thickening agent, such as beeswax, hard paraffin or cetyl alcohol. Sweetening agents, such as those set forth above, and flavoring agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an antioxidant such as ascorbic acid.
[0072] Dispersible powders and granules of the invention suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, a suspending agent, and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those disclosed above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
[0073] The pharmaceutical compositions of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil, such as olive oil or arachis oil, a mineral oil, such as liquid paraffin, or a mixture of these. Suitable emulsifying agents include naturally-occurring gums, such as gum acacia and gum tragacanth, naturally occurring phosphatides, such as soybean lecithin, esters or partial esters derived from fatty acids and hexitol anhydrides, such as sorbitan monooleate, and condensation products of these partial esters with ethylene oxide, such as polyoxyethylene sorbitan monooleate. The emulsion may also contain sweetening and flavoring agents.
[0074] Syrups and elixirs may be formulated with sweetening agents, such as glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative, a flavoring or a coloring agent.
[0075] The pharmaceutical compositions of the invention may be in the form of a sterile injectable preparation, such as a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally acceptable diluent or solvent, such as a solution in 1,3-butanediol or prepared as a lyophilized powder. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile fixed oils may conventionally be employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid may likewise be used in the preparation of injectables.
[0076] The amount of active ingredient that may be combined with the carrier material to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. For example, a time-release formulation intended for oral administration to humans may contain approximately 1 to 1000 mg of active material compounded with an appropriate and convenient amount of carrier material which may vary from about 5 to about 95% of the total compositions. The pharmaceutical composition can be prepared to provide easily measurable amounts for administration. For example, an aqueous solution intended for intravenous infusion should contain from about 3 to 330 μg of the active ingredient per milliliter of solution in order that infusion of a suitable volume at a rate of about 30 mL/hr can occur.
[0077] As noted above, formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous or non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be administered as a bolus, electuary or paste.
[0078] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free flowing form such as a powder or granules, optionally mixed with a binder (e.g., povidone, gelatin, hydroxypropylmethyl cellulose), lubricant, inert diluent, preservative, disintegrant (e.g., sodium starch glycolate, cross-linked povidone, cross-linked sodium carboxymethyl cellulose) surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide slow or controlled release of the active ingredient therein using, for example, hydroxypropyl methylcellulose in varying proportions to provide the desired release profile. Tablets may optionally be provided with an enteric coating, to provide release in parts of the gut other than the stomach. This is particularly advantageous with the compounds of formula I when such compounds are susceptible to acid hydrolysis.
[0079] Formulations suitable for topical administration in the mouth include lozenges comprising the active ingredient in a flavored base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerin, or sucrose and acacia; and mouthwashes comprising the active ingredient in a suitable liquid carrier.
[0080] Formulations for rectal administration may be presented as a suppository with a suitable base comprising for example cocoa butter or a salicylate.
[0081] Formulations suitable for vaginal administration may be presented as pessaries, tampons, creams, gels, pastes, foams or spray formulations containing in addition to the active ingredient such carriers as are known in the art to be appropriate.
[0082] Formulations suitable for parenteral administration include aqueous and non-aqueous isotonic sterile injection solutions which may contain antioxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose sealed containers, for example, ampoules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of the sterile liquid carrier, for example water for injections, immediately prior to use. Injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
[0083] Suitable unit dosage formulations are those containing a daily dose or unit, daily sub-dose, or an appropriate fraction thereof, of a compound of Formula I.
[0084] It will be understood, however, that the specific dose level for any particular patient will depend on a variety of factors including the activity of the specific compound employed; the age, body weight, general health, sex and diet of the individual being treated; the time and route of administration; the rate of excretion; other drugs which have previously been administered; and the severity of the particular disease undergoing therapy, as is well understood by those skilled in the art.
[0085] In one variation of the compounds of Formula I, X is NR 1 such that representative allosteric α7nAChR modulators of this invention include compounds having the structure of Formula II:
[0000]
[0086] In another variation of the compounds of Formula I, X is NR 1 and R 3 is
[0000]
[0000] such that representative allosteric α7nAChR modulators of this invention include compounds having the structure of Formula IIA:
[0000]
[0087] In yet another variation of the compounds of Formula I, X is O, such that representative allosteric α7nAChR modulators of this invention include compounds having the structure of Formula III:
[0000]
[0088] In still another variation of the compounds of Formula I, X is S, such that representative allosteric α7nAChR modulators of this invention include compounds having the structure of Formula IV:
[0000]
[0089] In one aspect, compounds of Formula I include:
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-pyridylmethylamino)-1,6-naphthyridine (Compound 1), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-pyridylmethylamino)-1,6-naphthyridine (Compound 2), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 3), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-propylamino-1,6-naphthyridine (Compound 4), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 5), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopropylamino-1,6-naphthyridine (Compound 6), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopentylamino-1,6-naphthyridine (Compound 7), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine (Compound 8), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-ethylamino-1,6-naphthyridine (Compound 9), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-fluorophenylamino)-1,6-naphthyridine (Compound 10), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine (Compound 11), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-tert-butylamino-1,6-naphthyridine (Compound 12), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine (Compound 13), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-methylamino-1,6-naphthyridine (Compound 14), 3-(4-Methoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 15), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-phenethylamino-1,6-naphthyridine (Compound 16), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 17), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 18), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine (Compound 19), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-ethylamino-1,6-naphthyridine (Compound 20), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylamino-1,6-naphthyridine (Compound 21), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine (Compound 22), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclobutylamino-1,6-naphthyridine (Compound 23), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-propylamino-1,6-naphthyridine (Compound 24), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopentylamino-1,6-naphthyridine (Compound 25), 3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-amino-1,6-naphthyridine (Compound 26), 3-(p-Tolyl)-1,4-dihydro-4-oxo-5-phenethylamino-1,6-naphthyridine (Compound 27), 3-(4-Chlorophenyl)-1,4-dihydro-1-benzyl-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 28), 3-(4-Chlorophenyl)-1,4-dihydro-1-cyclopropylmethyl-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 29), 3-(4-Chlorophenyl)-1,4-dihydro-1-butyl-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 30), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-phenethylamino-1,6-naphthyridine (Compound 31), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-benzylamino-1,6-naphthyridine (Compound 32), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine (Compound 33), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-ethyl-4-oxo-5-phenethylamino-1,6-naphthyridine (Compound 34), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-propylamino-1,6-naphthyridine (Compound 35), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclobutylamino-1,6-naphthyridine (Compound 36), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-ethylamino-1,6-naphthyridine (Compound 37), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopropylamino-1,6-naphthyridine (Compound 38), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine (Compound 39), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopentylamino-1,6-naphthyridine (Compound 40), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 41), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine (Compound 42), 3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-(3-pyridylamino)-1,6-naphthyridine (Compound 43); 3-(4-Methoxyphenyl)-1,4-dihydro-1-ethyl-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 44), 3-(4-Trifluoromethylphenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine (Compound 45), 3-(4-Trifluoromethylphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine (Compound 46), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-chlorophenylamino)-1,6-naphthyridine (Compound 47), 3-(4-Fluorophenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine (Compound 48), 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine (Compound 49), 3-(4-Chlorophenyl)-1,4-dihydro-1-methyl-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine (Compound 50) and 3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(3-chlorophenylamino)-1,6-naphthyridine (Compound 51).
[0141] In one aspect, there is provided pharmaceutical compositions comprising a compound of Formula I, II, IIa, III, or IV. In another aspect, there is provided a method for the treatment of disorders amenable to modulation of the α7nAChR comprising administering to a patient in need of such treatment a compound of Formula I, II, IIa, III, or IV or a pharmaceutically acceptable salt, ester, solvate or prodrug thereof. In one embodiment, the disorder is a neurodegenerative disorder. In another embodiment, the disorder is a senile dementia. In another embodiment, the disorder is schizophrenia. In another embodiment, the disorder is a cognition deficit disorder. In another embodiment, the disorder is Alzheimer's disease. In another embodiment, the disorder is related to learning. In another embodiment, the disorder is selected from the group consisting of memory loss, Lewy Body dementia, attention-deficit disorder, attention deficit hyperactivity disorder, anxiety, mania, manic depression, Parkinson's disease, Huntington's disease, amyotrophic lateral sclerosis, brain inflammation and Tourette's syndrome. In another embodiment, the disorder is pain, inflammation, septic shock, ulcerative colitis or irritable bowel syndrome.
[0142] In another aspect, there is provided a method for the treatment of a cognitive disorder related to learning and memory comprising administering to a patient in need of such treatment a compound of Formula I, II, IIa, III, or IV or a pharmaceutically acceptable salt, ester, solvate or prodrug thereof. In one embodiment, the cognitive disorder is mild cognitive impairment, age related cognitive decline, senile dementia or Alzheimer's disease. In one embodiment the treatment of such disorders is achieved via modulation of mono and divalent cation conductance through the site mediating the action of a compound of Formula I, II, IIa, III, or IV. In yet another aspect, there is provided a method for the treatment of disorders which comprises administering to a patient in need of such treatment a compound of Formula I, II, IIa, III, or IV or a pharmaceutically acceptable salt thereof. In one embodiment, the compound of Formula I, II, IIa, III, or IV or a pharmaceutically acceptable salt thereof has activity to positively allosterically modulate currents at α7 nAChR. Administration of allosteric modulators described herein treating, controlling, ameliorating or reducing the risk of a disorder amenable to modulation of α7 nAChR.
[0143] For use in medicine, the salts of the compounds of Formula I, II, IIa, III, or IV will be pharmaceutically acceptable salts. Other salts may, however, be useful in the preparation of the compounds according to the invention or of their pharmaceutically acceptable salts. Suitable pharmaceutically acceptable salts of the compounds of this invention include acid addition salts which may, for example, be formed by mixing a solution of the compound according to the invention with a solution of a pharmaceutically acceptable acid such as hydrochloric acid, sulfuric acid, methanesulfonic acid, fumaric acid, maleic acid, succinic acid, acetic acid, benzoic acid, oxalic acid, citric acid; tartaric acid, or phosphoric acid. Furthermore, where the compounds comprises an acidic moiety, suitable pharmaceutically acceptable salts thereof may include alkali metal salts, e.g. sodium or potassium salts; alkaline earth metal salts, e.g. calcium or magnesium salts; and salts formed with suitable organic ligands, e.g. quaternary ammonium salts. Standard methods for the preparation of pharmaceutically acceptable salts and their formulations are well known in the art, and are disclosed in various references, including for example, “ Remington: The Science and Practice of Pharmacy ”, A. Gennaro, ed., 20 th edition, Lippincott, Williams & Wilkins, Philadelphia, Pa.
[0144] The present invention includes prodrugs of the compounds of Formula I, II, IIa, III, or IV above. In general, such prodrugs will be functional derivatives of these compounds that are readily convertible in vivo into the required compound of Formula I, II, IIa, III, or IV. Conventional procedures for the selection and preparation of suitable prodrug derivatives are described, for example, in “ Design of Prodrugs ”, ed. H. Bundgaard, Elsevier, 1985. Such prodrugs include but are not limited to ester prodrugs from alcohols and acids as well as phosphate prodrugs of alcohols, all of which are familiar to those of skill in the art. The prodrug can be formulated to achieve a goal of improved chemical stability, improved patient acceptance and compliance, improved bioavailability, prolonged duration of action, improved organ selectivity, improved formulation (e.g., increased hydrosolubility), and/or decreased side effects (e.g., toxicity).
[0145] Where the compounds of the present invention have at least one asymmetric center, they may accordingly exist as enantiomers. Where the compounds possess two or more asymmetric centers, they may additionally exist as diastereoisomers. It is to be understood that all such stereoisomers and mixtures thereof in any proportion are encompassed within the scope of the present invention. Where the compounds possess geometrical isomers, all such isomers and mixtures thereof in any proportion are encompassed within the scope of the present invention.
[0146] Tautomers of the compounds of the invention are encompassed by the present application. Thus, for example, a carbonyl includes its hydroxyl tautomer.
EXAMPLES
[0147] Standard procedures and chemical transformation and related methods are well known to one skilled in the art, and such methods and procedures have been described, for example, in standard references such as Fiesers' Reagents for Organic Synthesis , John Wiley and Sons, New York, N.Y., 2002; Organic Reactions , vols. 1-83, John Wiley and Sons, New York, N.Y., 2006; March J. and Smith M., Advanced Organic Chemistry, 6th ed., John Wiley and Sons, New York, N.Y.; and Larock R. C., Comprehensive Organic Transformations , Wiley-VCH Publishers, New York, 1999. All texts and references cited herein are incorporated by reference in their entirety.
[0148] Reactions using compounds having functional groups may be performed on compounds with functional groups that may be protected. A “protected” compound or derivatives means derivatives of a compound where one or more reactive site or sites or functional groups are blocked with protecting groups. Protected derivatives are useful in the preparation of the compounds of the present invention or in themselves; the protected derivatives may be the biologically active agent. An example of a comprehensive text listing suitable protecting groups may be found in T. W. Greene, Protecting Groups in Organic Synthesis, 3rd edition, John Wiley & Sons, Inc. 1999.
[0149] Compounds of Formula III′ can be prepared as shown in Scheme 1, starting with commercially available 2,4-dichloropyridines of formula A. Treatment of an appropriately substituted 2,4-dichloropyridine of formula A with a base such as lithium diisopropylamide in THF at −65° C. to −78° C. followed by addition of CO 2 and acidification upon workup provides the corresponding nicotinic acid of formula B which is further converted to the acid chloride by oxalyl chloride treatment (cf Dai, Bioorg. Med. Chem. Lett. 2008, 18, 386-390). Condensation with an appropriately substituted phenyl acetate yields a β-ketoester which is decarboxylated at elevated temperature to give the desired compounds of formula C (cf Perner, J. Med. Chem., 2003, 46, 5249-5256). Condensation with ethyl formate (Becalli, J. Org. Chem. 1984, 49, 4287-4290) followed by regioselective ring closure under basic conditions provides the compounds of formula E (cf Burgart, Mendeleev Communications, 2001, 76). Further reaction with an appropriate amine leads to molecules of Formula III′ (cf Giannouli, J. Med. Chem., 2007, 50, 1716-1719).
[0000]
[0150] Compounds of Formula IV′ can be prepared as shown in Scheme 2, starting with compounds of formula C. Condensation with dimethylformamide dimethyl acetal followed by treatment with hydrogen sulfide provides compounds of formula E′ (cf Wentland, J. Med. Chem., 1993, 36, 2801-2809). Further reaction with an appropriate amine leads to compounds of formula IV′ (cf Croisy-Delcet, Heterocycles, 1991, 32, 1933-1945).
[0000]
[0151] Compounds of Formula IIA′ were prepared as shown in Scheme 3, starting with ethyl or methyl phenylacetates. The esters are commercially available or were prepared from the corresponding phenylacetic acid using well known literature methods (e.g. EtOH or MeOH/H 2 SO 4 ). Reaction of the ethyl phenylacetates with ethyl formate was carried out according to the procedure of Beccalli, et al. J. Org. Chem. 1984, 49, 4287-4290, to give a hydroxymethylene intermediate. Reaction with a 2-chloro-4-aminopyridine then afforded the desired condensation product, which was cyclized in refluxing phenyl ether to give E′. Addition of an amine R 4 NH 2 in DMSO with heating then gave the desired compound of Formula IIA′.
[0000]
[0152] Oocyte Electrophysiology:
[0153] Individual compounds were tested for modulation of submaximal nicotine-evoked currents at α7 nAChRs using oocytes expressing human receptors. For each oocyte, the maximal nicotine-evoked currents were determined in response to 3 mM nicotine. All other currents were scaled to this value. The concentration of nicotine was adjusted to evoke a fractional current of approximately 0.05 (5% of max, or “EC 5 ”), and this concentration of nicotine was used to generate EC 5 control currents. Increasing concentrations of test compounds were applied to oocytes alone (pretreatment) and then in combination with the EC 5 concentration of nicotine (co-application). This protocol allowed measurement of both direct effects of test compounds on α7 nAChRs, and modulatory effects of compounds on nicotine-evoked responses. mRNA was prepared and stored using conventional techniques from cDNA clones encoding the human nicotinic receptor subunits. Preparation, micro-injection and maintenance of oocytes were performed as reported in detail previously (Whittemore et al., Mol. Pharmacol. 50: 1364-1375, 1996). Individual oocytes were injected with 5-50 ng of each subunit mRNA. For multiple subunit combinations, the mRNA ratios are: (1) α4β2 and α3β4 nAChRs (a 1:1 mixture); following injections, oocytes were maintained at 16-17° C. in Barth's medium. Two-electrode voltage clamp recordings were made 3-14 days following mRNA injections at a holding voltage of −70 mV unless specified. The nicotinic recordings were done in Ca ++ -free Ringer solution (mM: NaCl, 115; KCl, 2; BaCl 2 , 1.8; HEPES, 5; pH 7.4) to limit Ca ++ -activated chloride and muscarinic currents. Drug and wash solutions were applied using a microcapillary “linear array” (Hawkinson et al., Mol. Pharmacol. 49: 897-906, 1996) in order to allow rapid application of agonists. Currents were recorded on a chart recorder and/or PC-based computer for subsequent analysis. Test compounds were made up in DMSO over a concentration range of 0.001-10 mM and diluted 1000-3000-fold into the appropriate saline just prior to testing (final [DMSO]≦0.1%). The concentration-dependence of modulation was analyzed using GraphPad “Prism” curve-fitting software. Compounds of the present invention show at least 100% modulation of the nicotine EC 5 at 10 μM.
[0154] The compounds of the present invention exhibit either at least 100% positive modulation or from 10% to 50% negative modulation of the nicotine EC 5 at 10 μM. Certain compounds of the present invention exhibit at least 500% positive modulation of the nicotine EC 5 at 10 μM.
[0155] Positive allosteric modulators can also be assayed by imaging of calcium flux through α7 nAChR transiently expressed in a cell line, including HEK-293 and cell cultured neurons (see for example WO 2006/071184). Activation of native α7 nAChRs, by electrophysiological recordings in rat hippocampal slices can also be used to measure the effect of allosteric modulators. The effect can be observed on the activation of α7 nAChR mediated currents in hippocampal CA1 stratum radiatum interneurons by the application of ACh in the presence of an allosteric modulator.
Example 1
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine
[0156]
Ethyl α-[[(2-chloro-4-pyridinyl)amino]methylene]-(4-chlorophenyl)acetate
[0157] A solution of ethyl (4-chlorophenyl)acetate (10.87 g, 54.72 mmol) in 90 mL of ethyl formate was treated with a 60% suspension of NaH in oil (7.0 g, 175 mmol) added in portions. After stirring overnight, the reaction was added to 130 mL of 10% aq. HCl and 70 mL of water. The resulting mixture was extracted with EtOAc (3×50 mL). The pooled EtOAc layers were washed with water and brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was treated with solid 4-amino-2-chloropyridine (7.08 g) and 100 mL of EtOH. After 48 h at reflux, the reaction was allowed to cool to room temperature. After standing overnight, the precipitate that formed by isolated and washed with EtOH, affording 8.0 g of the desired product.
5-Chloro-3-(4-chlorophenyl)-1,4-dihydro-4-oxo-1,6-naphthyridine
[0158] Solid ethyl α-[[(2-chloro-4-pyridinyeamino]methylene]-(4-chlorophenyl)acetate (4.0 g) was added in portions to refluxing phenylether (50 mL). After 20 min at reflux, the reaction was allowed to cool and diluted with hexanes. The precipitate that formed was collected and washed with hexanes. Purification by preparative RPHPLC gave the title compound as a light yellow solid.
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine
[0159] A solution of 5-chloro-3-(4-chlorophenyl)-1,4-dihydro-4-oxo-1,6-naphthyridine (158 mg, 0.545 mmol) and phenethylamine (350 μL) in 2 mL of DMSO was heated at 125° C. for 1 h. Purification by preparative HPLC gave the title compound as a light yellow solid. MS 376 (M+1) + .
[0160] The following compounds were prepared by using the procedure described above:
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-pyridylmethylamino)-1,6-naphthyridine
[0161] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 2-(aminomethyl)pyridine. MS 363 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-pyridylmethylamino)-1,6-naphthyridine
[0162] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 4-(aminomethyl)pyridine. MS 363 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine
[0163] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with aniline. MS 348 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-propylamino-1,6-naphthyridine
[0164] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with propylamine. MS 314 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine
[0165] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with benzylamine. MS 362 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopropylamino-1,6-naphthyridine
[0166] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with cyclopropylamine. MS 312 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopentylamino-1,6-naphthyridine
[0167] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with cyclopentylamine. MS 340 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine
[0168] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with cyclopropylmethylamine. MS 326 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-ethylamino-1,6-naphthyridine
[0169] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with ethylamine. MS 300 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-fluorophenylamino)-1,6-naphthyridine
[0170] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 4-fluoroaniline. MS 366 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine
[0171] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 4-chloroaniline. MS 382 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-tert-butylamino)-1,6-naphthyridine
[0172] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with tert-butylamine. MS 328 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-cyclohexylmethylamino)-1,6-naphthyridine
[0173] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with cyclohexylmethylamine. MS 368 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-methylamino-1,6-naphthyridine
[0174] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with methylamine. MS 286 (M+1) + .
3-(4-Methoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine
[0175] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-methoxyphenyl)acetate and phenethylamine was replaced with aniline. MS 378 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-phenethylamino-1,6-naphthyridine
[0176] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate. MS 386 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine
[0177] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with aniline. MS 358 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine
[0178] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with benzylamine. MS 372 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine
[0179] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with cyclohexylmethylamine. MS 378 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-ethylamino-1,6-naphthyridine
[0180] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with ethylamine. MS 310 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylamino-1,6-naphthyridine
[0181] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with cyclopropylamine. MS 322 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine
[0182] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with cyclopropylmethylamine. MS 336 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclobutylamino-1,6-naphthyridine
[0183] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with cyclobutylamine. MS 336 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-propylamino-1,6-naphthyridine
[0184] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with propylamine. MS 324 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopentylamino-1,6-naphthyridine
[0185] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with cyclopentylamine. MS 350 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-4-oxo-5-amino-1,6-naphthyridine
[0186] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-ethoxyphenyl)acetate and phenethylamine was replaced with ammonia. MS 282 (M+1) + .
3-(p-Tolyl)-1,4-dihydro-4-oxo-5-phenethylamino-1,6-naphthyridine
[0187] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-tolyl)acetate. MS 356 (M+1) + .
3-(4-Trifluoromethylphenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine
[0188] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-trifluoromethyl-phenyl)acetate and phenethylamine was replaced with 4-chloroaniline. MS 416 (M+1) + .
3-(4-Trifluoromethylphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine
[0189] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-trifluoromethyl-phenyl)acetate and phenethylamine was replaced with aniline. MS 382 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(2-chlorophenylamino)-1,6-naphthyridine
[0190] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 2-chloroaniline. MS 382 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-4-oxo-5-(3-chlorophenylamino)-1,6-naphthyridine
[0191] The title compound was prepared as described in Example 1 above except that phenethylamine was replaced with 3-chloroaniline. MS 382 (M+1) + .
3-(4-Fluorophenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine
[0192] The title compound was prepared as described in Example 1 above except that ethyl (4-chlorophenyl)acetate was replaced with ethyl (4-fluorophenyl)acetate and phenethylamine was replaced with 4-chloroaniline. MS 366 (M+1) + .
Example 2
3-(4-Chlorophenyl)-1,4-dihydro-1-methyl-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine
[0193]
[0194] A solution of 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine (57 mg, 0.15 mmol) in 2 mL of DMF was treated with solid K 2 CO 3 (21 mg) and iodomethane (10 μL). After stirring overnight, the title compound was isolated by preparative RPHPLC. MS 390 (M+1) + .
[0195] The following compounds were prepared by using the procedure described above:
3-(4-Chlorophenyl)-1,4-dihydro-1-benzyl-4-oxo-5-benzylamino-1,6-naphthyridine
[0196] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine and iodomethane was replaced with benzyl chloride. MS 462 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-1-cyclopropylmethyl-4-oxo-5-benzylamino-1,6-naphthyridine
[0197] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine and iodomethane was replaced with cyclopropylmethyl bromide. MS 426 (M+1) + .
3-(4-Chlorophenyl)-1,4-dihydro-1-butyl-4-oxo-5-benzylamino-1,6-naphthyridine
[0198] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine and iodomethane was replaced with iodobutane. MS 428 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-phenethylamino-1,6-naphthyridine
[0199] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine. MS 400 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-benzylamino-1,6-naphthyridine
[0200] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-benzylamino-1,6-naphthyridine. MS 387 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine
[0201] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclohexylmethylamino-1,6-naphthyridine. MS 393 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-ethyl-4-oxo-5-phenethylamino-1,6-naphthyridine
[0202] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine and iodomethane was replaced with iodoethane. MS 414 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-propylamino-1,6-naphthyridine
[0203] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-propylamino-1,6-naphthyridine. MS 338 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclobutylamino-1,6-naphthyridine
[0204] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclobutylamino-1,6-naphthyridine. MS 350 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-ethylamino-1,6-naphthyridine
[0205] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-ethylamino-1,6-naphthyridine. MS 324 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopropylamino-1,6-naphthyridine
[0206] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylamino-1,6-naphthyridine. MS 336 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine
[0207] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopropylmethylamino-1,6-naphthyridine. MS 350 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-cyclopentylamino-1,6-naphthyridine
[0208] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-cyclopentylamino-1,6-naphthyridine. MS 364 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-phenylamino-1,6-naphthyridine
[0209] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine. MS 372 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine
[0210] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-(4-chlorophenylamino)-1,6-naphthyridine. MS 406 (M+1) + .
3-(4-Ethoxyphenyl)-1,4-dihydro-1-methyl-4-oxo-5-(3-pyridylamino)-1,6-naphthyridine
[0211] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-ethoxyphenyl)-1,4-dihydro-4-oxo-5-(3-pyridylamino)-1,6-naphthyridine. MS 373 (M+1) + .
3-(4-Methoxyphenyl)-1,4-dihydro-1-ethyl-4-oxo-5-phenylamino-1,6-naphthyridine
[0212] The title compound was prepared as described in Example 2 above except that 3-(4-chlorophenyl)-1,4-dihydro-4-oxo-5-(2-phenethylamino)-1,6-naphthyridine was replaced with 3-(4-methoxyphenyl)-1,4-dihydro-4-oxo-5-phenylamino-1,6-naphthyridine and iodomethane was replaced with iodoethane. MS 372 (M+1) + .
[0213] The patents and publications listed herein describe the general skill in the art and are hereby incorporated by reference in their entireties for all purposes and to the same extent as if each was specifically and individually indicated to be incorporated by reference. In the case of any conflict between a cited reference and this specification, the specification shall control. In describing embodiments of the present application, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.
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The present application is related to compounds represented by Formula I, which are novel allosteric modulators of α7nAChR. The application also discloses the treatment of disorders that are responsive to modulation of acetylcholine action on α7nAChR in a mammal by administering an effective amount of a compound of Formula I.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO MICROFICHE APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to exercise apparatus used to develop and maintain muscular strength.
It has long been recognized that various types of exercise apparatus can be used by individuals desiring to increase and maintain muscular strength. Such exercise apparatus may be very simple and comprise dead weights that are lifted with the arms and legs, or large rubber bands that can be stretched to provide resistance, thereby increasing muscular strength.
Dead weights may be as simple as plastic bottles filled with water and with each bottle being individually grasped by a user's hands to be elevated in exercises that will develop muscular strength. The dead weights may also be heavier bar bells that are to be individually lifted by hand, or may comprise a long shaft with one or more weights affixed to each end of the shaft, with the shaft and weights being raised and lowered by a user in the development and maintenance of muscles in various parts of the body.
The large rubber bands, used for exercise purposes, may be stretched using arms, legs and other body parts, with the stretching action of the bands providing resistance that will develop muscular strength, or that will maintain desired strength. The large rubber bands can also be attached to a fixed structure, such as a door knob, or the like, and the user may stretch the attached rubber band to provide resistance and muscular development or maintenance.
A great many exercise machines and apparatus have also been proposed in the past. Such machines and apparatus frequently obtain essential the same results as the basic dead weight lift system and rubber band stretching system. However, the machines and/or apparatus that have been developed are frequently large, bulky and heavy, and must be used in a pre-determined location. Often it is not practical to try and transport the machine or exercise apparatus since it is too bulky, and too heavy.
There remains a need for an effective exercise apparatus that can be easily transported by a user from location to location. A user who is traveling from location to location often needs or desires an exercise apparatus that can be easily and quickly set up for use in a bedroom, a hotel room, or any convenient space and that can be disassembled to be easily carried from location to location.
BRIEF SUMMARY OF THE INVENTION
1. Objects of the Invention
Principal objects of the present invention are to provide an exercise apparatus that is lightweight and compact so that it can be conveniently carried from location to location. It is another object to provide an exercise apparatus that can be readily set up for use, and that will allow the user to perform a wide variety of exercises to achieve development and maintenance of muscular strength of diverse muscles and muscle groups.
Other objects are to provide an exercise apparatus that is inexpensive, as compared to larger, more bulky exercise apparatus.
Still another object is to provide an exercise apparatus that will allow the user to perform many exercises that cannot be performed with more simple exercise apparatus, such as dead weights and large rubber bands.
Yet another object is to provide an exercise apparatus that can easily be used to exercise a wide variety of muscles, even in a limited space, such as a bedroom, or hotel room.
2. Features of the Invention
Principal features of the invention include an elongate staff that is constructed from easily assembled components that are light in weight and easy to assemble.
Other features include at least one long stretch band formed of resilient tubing that is stretched through end pieces fixed to opposite ends of the staff. The long stretch band is formed as an endless band that when fitted to the staff and relaxed has opposite sides lying against the length of the staff and sleeve-sliders mounted on the staff.
Sleeve-sliders slide onto opposite ends of the staff to provide adjustable gripping surfaces on the staff. The sleeve-sliders are movable along the staff to be spaced apart a distance that will allow convenient and comfortable grasping during a performance of many different exercises by a user.
The spaced sleeve-sliders also serve as sliding members and when grasped, together with the adjacent side lengths of the long stretch band, can be moved along the staff towards and away from one another. The sliding movement stretches portions of the long stretch band and provides resistance to strengthen upper body muscles used in performing the movements.
A shorter stretch band formed of resilient tubing is provided at each end of the staff, and the long stretch band and the shorter stretch bands are each secured in and project from caps affixed to opposite ends of the staff.
With the exercise apparatus of the invention, a user may exercise virtually every muscle and each muscle group of the body.
Additional objects and features of the invention will become apparent to persons skilled in the art to which the invention pertains from the following detailed description, drawings and claims.
BRIEF DESCRIPTION OF THE FIGURES OF THE INVENTION
In the Drawings
FIG. 1 , is an exploded, perspective view of the components of the exercise apparatus of the invention;
FIG. 2 , is a perspective view of the exercise apparatus of the invention with the components assembled;
FIG. 3 , a side elevation view of the exercise apparatus;
FIG. 4 , a view like that of FIG. 3 , but showing the long stretch band pulled away from opposite sides of the staff;
FIG. 5 , a view like that of FIG. 3 , but showing the sleeve-sliders positioned closer to the center point of the staff;
FIG. 6 , a view like that of FIGS. 3 and 5 , but showing the sleeve-sliders in a position;
FIG. 7 , a pictorial view showing a user performing a exercise, using the exercise apparatus of the invention;
FIG. 8 , a view like that of FIG. 7 , but showing the user performing a different exercise;
FIG. 9 , a view like that of FIG. 7 , but showing a user performing another exercise;
FIG. 10 , another view like that of FIG. 7 , but showing the user performing yet another exercise;
FIG. 11 , a view like that of FIG. 7 , but showing the user performing still another exercise with the exercise apparatus of the invention.
FIG. 12 , a pictorial view showing the user performing another exercise with the exercise apparatus of the invention; and
FIG. 13 , a pictorial view showing the user performing still another exercise with the exercise apparatus of the invention.
DETAILED DESCRIPTION
Referring Now the Drawings
The exercise apparatus 20 of the invention includes a staff 22 formed from a pair of straight, rigid limbs 24 and 26 .
Limb 24 is tubular and includes a non-threaded end 28 and an exteriorly threaded end 30 . Similarly, limb 26 is tubular and includes a non-threaded end 32 and an exteriorly threaded end 34 .
Limbs 24 and 26 are connected end-to-end axially together with a coupler 36 . Coupler 36 is tubular and has am outer diameter to just tightly fit into the open ends 28 and 32 of the limbs 24 and 26 , respectively. A central collar 38 is formed on, or affixed to, the coupler 36 , intermediate the length of the coupler. In assembling the limbs 24 and 26 to form the staff 22 , the end 40 of coupler 36 is inserted into the end 28 of limb 24 . The end 32 of limb 26 is telescoped onto the end 42 of coupler 36 . The limbs 24 and 26 are pushed into engagement with collar 38 .
A sleeve-slider 46 has a bore 48 therethrough. Bore 48 has an inside diameter that is just larger than the exterior diameter of limb 24 . Sleeve-slider 46 telescopes over threaded end 30 of the limb 24 and onto limb 24 .
Similarly, a sleeve-slider 50 has a bore 52 therethrough that has an inside diameter that is just larger than the outside diameter of limb 26 . Sleeve-slider 50 telescopes over threaded end 34 of limb 26 and onto limb 26 .
An end cap 54 has a bore 56 therethrough and bore 56 is interiorly threaded at one end 58 so that the end cap will thread onto threaded end 30 of limb 24 . The other end 59 of end cap 54 is non-threaded.
Another end cap 60 has a bore 62 therethrough. Bore 62 is interiorly threaded at one end 64 to be threaded onto the threaded end 34 of limb 26 . The other end 65 of end cap 60 is non-threaded.
Each end cap 54 and 60 has a pair of axially spaced holes 68 and 70 . Each hole 68 and 70 extends fully through the end cap transverse to the axis of the staff 22 . Each end cap 54 and 60 also has a narrow slot 72 extending from the non-threaded end 59 and 65 , respectively, of the end caps into engagement with the holes at opposite sides of the end cap.
A long endless stretch band 80 formed of resilient tubing, i.e., surgical rubber tubing, has side lengths 82 and 84 , and ends 86 and 88 interconnecting the side lengths. The overall length between ends of the long endless stretch band 80 is such that when the exercise apparatus 20 is assembled, the side lengths 82 and 84 and band 80 are lightly stretched between ends 86 and 88 such that the side lengths are close to the shaft and the sleeve-sliders 46 and 50 .
Handles 90 and 92 are respectively formed around the mid-portions of the side lengths 82 and 84 to provide hand grips for a user, as will be further described.
A short endless stretch band 96 formed as an endless loop 98 and also made of a stretchable material such as surgical rubber tubing, has a handle 100 formed around a middle portion of loop 98 to be grasped by a user.
Similarly, a short endless stretch band 106 formed as an endless loop 108 , made of stretchable material, such as surgical rubber tubing has a handle 110 formed around a middle portion of the loop 108 to be grasped by a user.
When disassembled, the exercise apparatus, as shown in FIG. 1 , comprises small, lightweight components that can easily be carried by a user. A carry bag, not shown, may be used to hold the components together for storage and transport.
The most bulky components used to make the exercise apparatus are the limbs 24 and 26 , which may each have a length of, for example, between about thirty-five and forty-five cm. When assembled as staff 22 , to include end caps 54 end 60 , the overall length of between eighty and one-hundred cm allows the staff to best function as necessary when the bands are stretched and/or pulled from the end caps during performance of exercises. The limbs 24 and 26 are preferably made of aluminum, plastic or other suitable lightweight material that will not bend or break during use of the exercise apparatus 20 .
Typical exercises that can be performed using the exercise apparatus 20 are shown in FIGS. 4 and 7 - 13 .
FIGS. 4 and 13 show that in use of the exercise apparatus 20 , the side lengths 82 and 84 of the long stretch band 80 can be simultaneously spread outwardly from opposite sides of the staff 22 . The side lengths 82 and 84 are stretched outwardly, in opposite directions, using handles 90 and 92 and are then relaxed. The stretching and relaxing can be accomplished while a user is reclining, sitting, or standing and the staff 22 floats and is not anchored.
As shown in FIG. 7 , a user 120 in a sitting position can place the staff 22 against the bottom of his feet 122 to secure the staff in place. The short endless stretch bands 96 and 106 are stretched by a user 120 grasping handles 100 and 110 in his hands 126 and 128 and pulling and relaxing the bands simultaneously, or in sequence.
Another typical exercise performed by a user with exercise apparatus 20 is shown in FIG. 8 . As shown, the user sits on the staff 22 , places short stretch bands 96 and 106 over feet 122 so that the user can spread, push or otherwise stretch and relax the short stretch bands 96 and 106 simultaneously, or in sequence, using his legs.
FIGS. 9 , 10 and 12 show use of the exercise apparatus 20 being raised and lowered in front of the user ( FIG. 9 ), and above the head of the user ( FIG. 10 ). The exercise apparatus can thus be used as a dead weight to perform some exercises. Alternatively, as shown in FIGS. 9 , 10 and 12 , the user can stand on the side length 84 and then raise and lower the staff 22 between a lowered position and an overhead raised position ( FIG. 10 ), and a raised position in front of his body ( FIGS. 9 and 12 ). It will be apparent that while the exercises of FIGS. 9 , 10 and 12 show lifting of the staff 22 in front of the user, that lifts behind the user's head can also be performed. It will also be apparent that the user can change the exercises by choosing to use either an overhead grip or an underhand grip.
FIG. 11 shows still another typical exercise that can be performed with the exercise apparatus 20 . As shown, the staff 22 is positioned behind the shoulders of a user. The user 120 grasps handles 100 and 110 and moves his arms and hands 126 and 128 to stretch the bands 96 and 106 .
Also, as shown in FIGS. 9 , 10 and 12 , the user can while the staff is positioned in front, above, or behind his body, grasp the sleeve-sliders 46 and 50 , together with the side lengths 82 and 84 of long stretch band 80 lying alongside the staff and sleeve-sliders. Then, either while lifting and lowering the staff 22 , or while holding the staff at a desired height, the sleeve-sliders 46 and 50 are moved forward or away from one another. Such movement of the sleeve-sliders, while stretching the portions of the long resilient band side lengths between the end caps and the sleeve-sliders, or the portions of the slide lengths 82 and 84 between sleeve-sliders exercises the arms and upper body muscles of the user.
The user 120 shown in FIG. 12 is standing on the side length 84 of the long resilient, endless stretch band 80 while grasping the sleeve-sliders 46 and 50 , and the side length 82 . The user is thus able to exercise by lifting against the stretch of side length 84 and, at the same time, to exercise muscle of the hands, arms and upper body by moving the sleeve-sliders along the staff 22 , while grasping the sleeve-sliders and the side length 82 with an underhand grip.
The exercises shown herein are typical of, but are not in any way limiting, of exercises that can be performed using exercise apparatus 20 .
As previously noted, the exercise apparatus 20 is lightweight, and easily assembled for use, with stretch band 80 . The band 80 is stretched at its ends 86 and 88 until the ends are stretched thin enough to fit through slots 72 and into the end caps 54 and 60 until the long stretch band extends out of the holes 70 through both end caps 46 and 50 . While only one long stretch band 20 is shown, it will be apparent that more than one such band can be provided to provide additional resistance during exercising if desired.
Short bands 96 and 106 are similarly stretched until the band portions opposite handles 100 and 110 are thin enough to slide through slots 72 to allow the short bands to extend through a hole 68 provided in each of the end caps 54 and 68 .
The exercise apparatus 20 does not require any tools in the assembly or disassembly of the apparatus.
Although a preferred embodiment of my invention has been herein described, it is to be understood that the present disclosure is by way of example and that variations are possible without departing from the subject matter coming within the scope of the following claims, which subject matter I regard as my invention.
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An exercise apparatus that is lightweight, easily transported, inexpensive and easy to use in performing a wide variety of exercises, the exercise apparatus including a rigid shaft formed of interconnectable limbs having a pair of spaced sleeve-sliders thereon and opposing end caps that receive a long resilient band having side lengths stretched along the staff and the sleeve-sliders thereon, and with each end cap also receiving a short resilient band with a handle thereon.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention relates to an antilock braking device for precluding the locking of the wheels of a vehicle on sudden application of the brake and a road surface friction sensor and a road surface friction coefficient detector which can be used as components of said antilock braking device.
[0003] 2. Technical Background
[0004] The conventional antilock braking device for cars or other vehicles generally employs a system such that the braking action is automatically controlled according to the chassis speed and wheel speed in such a manner that the slip ratio will fall within a definite range (See, for example, Japanese Patent Publication No. 30585/1984 and Japanese laid-open Patent Application KOKAI No. 61354/1985). The relationship between road surface friction coefficient and slip ratio is variable according to the texture of the road surface and, for this reason, the above system does not always provide the maximum braking force depending on the condition of the road surface and, in such cases, does not insure the minimum braking distance. Furthermore, because the chassis speed value used is an approximate value estimated from the wheel speed, the precision of slip ratio control is not sufficiently high. In order to ascertain the exact chassis speed, one has to rely on complicated devices such as the ground relative speed sensor (for example, Japanese laid-open Patent Application No. 64861/1988) or chassis deceleration sensor (for example, Japanese laid-open Patent Application No. 170157/1988).
[0005] In the conventional antilock braking device described in Japanese laid-open Patent Application No. 25169/1988, the road surface friction torque acting on the wheel (tire torque) is calculated from the wheel angular acceleration and brake fluid pressure values and the beginning of a fall in tire torque during the elevation of brake fluid pressure is utilized as one of the criteria for ascertaining the condition immediately preceding a wheel lock. However, since the tire torque is indirectly calculated from the wheel angular acceleration and brake fluid pressure, the above system does not take care of indefinite constants such as the moment of inertia of the wheels, the braking efficiency of the brake and so on, thus presenting problems in terms of the accuracy of data. There also is the problem that since the distance between the wheel to the road surface varies according to the deceleration of the chassis depending on the pneumatic pressure of the tires and the weight of the chassis, the road surface friction force and the tire torque are not necessarily maintained in a fixed ratio.
[0006] It is an object of this invention to provide an antilock braking device free from the above-mentioned disadvantages of the conventional device.
[0007] It is another object to provide a road surface frictional force sensor and a road surface friction coefficient detector which can be used as components of said antilock braking device.
SUMMARY OF THE INVENTION
[0008] A first antilock braking device according to this invention includes a brake control means adapted to cyclically perform an operational series which comprises sensing the road surface frictional force, increasing the brake fluid pressure while the road surface frictional force is increasing in response to the elevation of brake fluid pressure, decreasing the brake fluid pressure when the road surface frictional force declines despite elevation of the brake fluid pressure, and increasing the brake fluid pressure again when the road surface frictional force decreases in response to a fall-off of brake fluid pressure. The road surface frictional force can be known from measured values of the tire strain or the strain around the wheel of the vehicle.
[0009] A second antilock braking device according to this invention includes a brake control means adapted to cyclically perform an operational series which comprises detecting the coefficient of road surface friction, increasing the brake fluid pressure while the road surface friction coefficient is increasing in response to the elevation of brake fluid pressure, relieving or releasing the brake fluid pressure as the velocity of gain in road surface friction coefficient falls below a set value and increasing the brake fluid pressure again after the road surface friction coefficient has declined below said set value. The road surface friction coefficient value used in this second antilock braking device can be calculated from the road surface frictional force value and the vertical load value obtainable from measured values of the tire strain or the strain around the wheel. The relationship between wheel-road surface slip ratio and road surface friction coefficient can be represented by curves such as shown in FIG. 1 . On the ordinary road surface, this relation can be expressed by a curve having a peak as shown at C 1 . On an extraordinary road surface, such as a snow-clad road surface, the relation may be represented by a curve without a peak as shown at C 2 . Not only the presence or absence of a peak but also the height of the peak and the magnitude of the slip ratio corresponding to the peak vary with the condition of the road surface and the chassis speed. On the other hand, as represented by curve C 3 , the cornering force (lateral drag) decreases monotonously in response to an increase in slip ratio. Therefore, as far as trackless vehicles such as automobiles are concerned, in order to obtain the maximum braking force without sacrificing the cornering force, it is ideal to apply the brake in the neighborhood of P 1 or P 2 on curve C 1 or C 2 as the case may be.
[0010] Let it be supposed that the vehicle is running on a road surface such that the relation between road surface friction coefficient and slip ratio can be represented by the curve C 1 shown in FIG. 1 . It should be understood that the road surface friction force is approximately proportional to the road surface friction coefficient. Under these conditions, the first anti-lock braking device according to this invention functions as follows. First, as a sudden brake is applied by depressing the brake pedal or manipulating the brake lever, the brake fluid pressure increases. While the detected road surface frictional force value continues to rise, the brake fluid pressure is increased consistently to apply the brake with an increasing force. This phase corresponds to the segment to the left of P 1 on the curve C 1 shown in FIG. 1 . As the brake fluid pressure is increased to apply the brake more forcefully, the slip ratio increases to approach to the point P 1 of maximum road surface friction coefficient. As the brake fluid pressure is further increased, the point P 1 is passed over in due course. Beyond P 1 , the locking of the wheels begins to occur as the road surface frictional force turns to decline against the elevation of brake fluid pressure. When the road surface friction sensor output decreases in this manner, the brake fluid pressure is decreased to releave the brake action. Therefore, the locking of the wheels is prevented. As the road surface frictional force decreases in response to a decline in brake fluid pressure, the brake fluid pressure is increased again. As the result of this action, as long as the vehicle runs on the road surface which can be represented by a curve with a peak in regard to the road surface friction coefficient-slip ratio relation, the locking of the wheels can be prevented irrespective of road condition and, moreover, the braking action making the most of road surface frictional force can be realized.
[0011] The frictional force which acts between each wheel of the vehicle and the road surface is dynamically equivalent to the braking force applied by the wheel on the chassis. Therefore, strains and stresses proportional to the road surface frictional force are generated in all given positions of the structure between the point of contact of the wheel with the road surface and the chassis. Therefore, it is possible for one to measure the structural strain at an appropriate point of the structure and detect the road surface frictional force through the strain value. The member of the structure in which the maximum strain is generated is the tire in case the vehicle has tires in its wheels. Therefore, the road surface frictional force can be detected from measured values of the tire strain. It is also possible to affix strain gauges to the bearing shaft supporting the wheel, for instance, and measure the strain around the wheel. This strain is smaller than the tire strain but since said shaft is not a rotary element, the construction of the road surface friction sensor can be simplified.
[0012] The vertical drag exerted by the road surface on each wheel, or the vertical load which the wheel applies to the road surface as a reaction thereto, can, for the same reason as above, also be detected from a measured value of the tire strain or the strain around the wheel.
[0013] The second antilock braking device according to this invention functions as follows. As the motorist depresses the brake pedal or manipulates the brake lever with a great force, the antilock braking device is started. In the segment to the left of P 1 or P 2 on curve C 1 or C 2 , the road surface friction coefficient p increases in response to an elevation of brake fluid pressure. However, when the velocity of gain in μ falls off below a predetermined reference level (slightly to the left of the point P 1 or at the point P 2 ), the brake fluid pressure is releaved or released, whereupon the value of μ turns to diminish. After a decline corresponding to a given proportion of the maximum value immediately preceding the beginning of decrease of the road surface friction coefficient μ, the brake fluid pressure begins to rise again. Thereafter, the above sequence of events is repeated. In this manner, not only when the vehicle is running on a road surface such that the relation between road surface friction coefficient and slip ratio traces the aforementioned curve C 1 but also when the road surface can be represented by curve C 2 without a peak, the road surface friction coefficient at application of the brake is maintained in the neighborhood of P 1 and P 2 , thus insuring a more or less ideal braking action. For vehicles (rolling stock, etc,) which run on tracks, in which no cornering force is required, said predetermined reference value for the velocity of gain in μ is set at zero or an appropriate negative value. Then, the braking action utilizing the maximum road surface friction force can be insured. The road surface friction coefficient value to be used in this second antilock braking device can be found by computation from the above-mentioned road surface frictional force value and the vertical load value obtainable through tire strain data or the data of strain around the wheel.
[0014] Thus, according to the device of this invention, the braking distance can be minimized irrespective of the condition of the road surface and, at the same time, the object of an antilock braking effect can be accomplished. Furthermore, the device does not require a complicated setup for measuring the chassis speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a diagrammatic representation of the relationship among slip ratio, road surface friction coefficient and cornering force;
[0016] FIG. 2 is a block diagram of the antilock braking device according to an embodiment of this invention;
[0017] FIG. 3 is a flow chart showing the execution of the program routine in the control means built into the antiblock braking device illustrated in FIG. 2 ;
[0018] FIG. 4 is a block diagram of the antilock braking device according to another embodiment of this invention;
[0019] FIG. 5 is a flow chart showing the execution of the main routine in the control means built into the antilock braking device illustrated in FIG. 4 ;
[0020] FIG. 6 is a flow chart showing the brake fluid depression routine of FIG. 5 in detail;
[0021] FIG. 7 is a flow chart showing the brake fluid recompression routine of FIG. 5 in detail;
[0022] FIG. 8 is a flow chart showing an interruption of the main routine shown in FIG. 5 ;
[0023] FIG. 9 is a front view showing the position of installation of strain gauges constituting the road surface friction coefficient detector embodying the principle of this invention for one rear wheel in the vicinity of the rear wheel;
[0024] FIG. 10 is a front view, on exaggerated scale, of the position of installation of the strain gauges illustrated in FIG. 9 ;
[0025] FIG. 11 is a plan view, on exaggerated scale, of the,position of installation of the strain gauges illustrated in FIG. 10 ;
[0026] FIG. 12 is a block diagram of the road surface friction coefficient detector embodying the principle of this invention as applicable to one rear wheel;
[0027] FIG. 13 is a front view showing another example of the installation of strain gauges in the vicinity of the rear wheel of a vehicle;
[0028] FIG. 14 is a front view showing the position of installation of strain gauges constituting the road surface friction coefficient detector embodying the principle of this invention for one front wheel in the vicinity of the front wheel;
[0029] FIG. 15 is a perspective view showing, on exaggerated scale, the position of installation of the strain gauges illustrated in FIG. 14 ;
[0030] FIG. 16 is a similar perspective view showing, on exaggerated scale, the position of installation of the strain gauges illustrated in FIG. 14 ;
[0031] FIG. 17 is a block diagram of the road surface friction coefficient detector embodying the principle of this invention as applicable to one front wheel;
[0032] FIG. 18 is a front view showing a further example of the installation of strain gauges in the vicinity of the front wheel of a vehicle;
[0033] FIG. 19 is a perspective view showing, on exaggerated scale, the position of installation of the strain gauges illustrated in FIG. 18 ; and
[0034] FIG. 20 is a schematic side-elevation view showing the displacement of the tire on application of the brake.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In the following description of embodiments, an automobile will be taken as an example. However, it should be understood that the present invention is applicable to other types of vehicles as well.
[0036] FIG. 2 and 3 illustrate an antilock braking device embodying the principle of this invention.
[0037] The control means 3 controls the pressure of brake fluid with reference to measured values of brake pedal depressing force, road surface frictional force and brake fluid pressure. A brake pedal depressing force sensor 2 , brake fluid pressure generator 4 , brake means 5 and brake fluid pressure sensor 6 may each be implemented by utilizing the known technologies. The control means 3 comprises an electronic circuit including a microprocessor, a memory and an input-output interface and functions according to program written into the memory. An example of the action of this control means 3 is illustrated in the flow chart of FIG. 3 . When the brake pedal-depressing force exceeds a set value, the antilock braking device of this invention is started to make a transition from the ordinary braking action to the antilock braking action. Referring to the flow chart of FIG. 3 , step 10 represents the beginning of the antilock braking action. Subsequently at step 12 , the road surface frictional force F is detected, and at step 14 , the above value is stored in a variable labeled with F t-1 . Then, at step 16 , the brake fluid pressure is increased. Further at step 18 the road surface frictional force F is detected, and at step 20 this road surface frictional force value is stored in a variable F t . Then, at step 22 , it is judged whether the difference between the two variable F t and F t-1 , viz. F t −F t-1 , is positive or negative. If it is positive, the stored value of variable F t-1 is updated to the value of variable F t at step 24 . Then, the sequence returns to step 16 . If the judgement at step 22 is not positive, the sequence proceeds to step 26 . At step 26 , just as at step 24 , the stored value of variable F t-1 is updated to the value of variable F t . Then, at step 28 , the brake fluid pressure is decreased. Thereafter, the road surface frictional force F is detected at step 30 and this value is stored in variable F t at step 32 . Subsequently at step 34 , as at step 22 , the value of difference F t −F t-1 is compared with zero. If the difference is negative, the sequence proceeds to step 24 . If the judgement at step 34 is not negative, the sequence returns to step 26 .
[0038] As the control means 3 executes the above program, the brake fluid pressure is controlled in such a manner that the brake will always be applied at or near the maximum road surface friction coefficient (P 1 on curve C 1 in FIG. 1 ) irrespective of the condition of the road surface.
[0039] However, the above embodiment has the following drawbacks (1) through (4).
[0040] (1) The antilock braking device according to the above embodiment functions in pursuit of the maximum value of road surface frictional force. Therefore, when the road surface has no peak of road surface friction coefficient relative to slip ratio as represented by curve C 2 in FIG. 1 , it may happen that ultimately a state of complete lock (slip ratio S=1) occurs to frustrate the object of an antilock brake.
[0041] (2) The road surface friction coefficient is the relative value of road surface frictional force to the vertical load acting on the wheel. However, since the vertical load which acts on the wheels during the running of the vehicle is not necessarily constant, the relation between road surface friction coefficient and road surface frictional force is not exactly proportional but merely approximately so. Therefore, it does not necessarily hold true that the antilock braking device of the above embodiment which pursues the maximum value of road surface frictional force pursues the peak point P 1 on the curve Cl shown in FIG. 1 . The antilock braking device described in Japanese laid-open Patent Application No. 25169/1988, which controls the braking action with reference to the brake torque of the wheel, also has a similar disadvantage.
[0042] (3) The above surface frictional force increases as the brake fluid pressure is increased. However, as moments of inertia around the axle exist in the wheel, there is a delay in the increases in slip ratio and road surface frictional force that follow the increasing brake fluid pressure. Therefore, when the point of braking action makes an ingress beyond and into the segment to the right of P 1 on the curve C 1 of FIG. 1 and the road surface friction coefficient (and the road surface frictional force, too, if the vertical load is constant) begins to decline, the brake fluid pressure may have reached an excessively high level. Therefore, even if a decline in road surface frictional force is detected at this time-point and the brake fluid pressure is accordingly relieved, it is not certain that the slip ratio immediately begins to decrease and the point of braking action reapproaches to P 1 from the right-hand side with a consequent upward turn of road surface frictional force. In other words, in the antilock braking device of the above embodiment in which the forthcoming decompression or compression of brake fluid is predicated on the increase or decrease in road surface frictional force in response to a fall-off of brake fluid pressure, it may happen that a complete lock occurs without a reapproach of the point of braking action, to P 1 from its right-hand side on the curve C 1 .
[0043] (4) Because of the absence of a means for sensing the stationary state of the vehicle, the unnecessary antilock braking action may continue to occur even after the vehicle has stopped to run.
[0044] An antilock braking device according to another embodiment of this invention, which has overcome the above-mentioned drawbacks is described hereinafter with reference to FIGS. 4 through 8 .
[0045] A control means 103 controls the brake fluid pressure with reference to measured values of brake pedal-depressing force, road surface friction coefficient μ, chassis speed detection signal and brake fluid pressure. A brake pedal-depressing force sensor 102 , brake fluid pressure generator 104 , brake fluid pressure sensor 107 and brake means 105 may all be implemented by utilizing the known technologies. The road surface friction coefficient and chassis speed detection signal are obtained from a road surface friction coefficient detector 101 and a chassis speed sensor 106 , both of which are described hereinafter in detail.
[0046] Like the above-mentioned control means 3 shown in FIG. 2 , the control means 103 comprises an electronic circuitry including a microprocessor, a memory and an input-output interface, and functions according to a program written into the memory. An example of the action of this control means 103 is shown in the flow charts of FIGS. 5 through 8 .
[0047] As the brake pedal-depressing force reaches a set value, the antilock braking device of this embodiment starts functioning to make a transition from the ordinary braking action to the antilock braking action. Referring to the main routine shown in FIG. 5 , step 110 represents the beginning of this antilock braking action. Subsequently at step 111 , the road surface friction coefficient μ is detected and at step 112 , this value of μ is stored in the variable labeled with μ t-1 . At step 113 , this value is stored in the variable labeled with μ p . Then, the brake fluid pressure is increased at step 115 and the value of μ is detected at step 116 . At step 117 , the value of μ detected at step 116 is stored in the variable labeled with μ t . The sequence proceeds to step 118 , where the difference μ t −μ t-1 between the two stored values μ t and μ t-1 is compared with a predetermined reference value μ c . If the difference μ t −μ t-1 is larger than μ c , the sequence proceeds to step 119 . If said difference is either equal to or smaller than μ c , the sequence proceeds to the brake fluid decompression routine at step 123 . At step 119 , the value stored in the variable μ t is stored in the variable μ t-1 and the stored value μ t-1 is updated. The sequence then returns to step 113 .
[0048] In the brake fluid decompression routine 123 , as illustrated in FIG. 6 the brake fluid pressure is either released or decreased to a given low level at step 142 . Then, μ is detected at step 143 and this detected value is stored in the variable μ t-1 at step 144 . The sequence then proceeds to step 146 where μ t-1 is compared with α·μ p . The coefficient α is a preset appropriate constant within the range of 0 to 1. If the variable μ t-1 is smaller, the sequence proceeds to step 149 to terminate the brake fluid decompression routine 123 and, then, to the brake fluid recompression routine at step 124 . If the variable μ t-1 is larger or equal, the sequence returns to step 142 .
[0049] In the brake fluid recompression routine 124 following the brake fluid decompression routine 123 , the operation illustrated in FIG. 7 is executed. First, at step 162 , the brake fluid pressure is increased. Then, μ is detected at step 163 and this value is stored in the variable μ t at step 164 . Thereafter, at step 165 , the variable μ t is compared with the variable μ t-1 . If the variable μ t is larger, the sequence proceeds to step 166 where the value of variable μ t is stored in the variable μ t-1 to update the stored value of variable μ t-1 . Then, the sequence proceeds to step 171 to terminate the brake fluid recompression routine and returns to the main routine at step 113 . If the variable μ t is found to be either smaller or equal at step 165 , the sequence proceeds to step 167 where, as at step 166 , the value of variable μ t-1 is updated to the value of μ t . The sequence then returns to step 162 .
[0050] As the control means 103 executes the above program, the antilock braking device according to this embodiment functions as follows. After the beginning of operation of the antilock braking device, the brake fluid pressure is increased while the rising velocity of road surface friction coefficient continues to exceed a predetermined reference value. As the rising velocity of road surface friction coefficient μ drops below said reference value, the brake fluid pressure is relieved or released. At this stage, the value of road surface friction coefficient μ immediately prior to the beginning of decline is memorized. This memorized value is referred to as μ p . When the road surface friction coefficient μ has declined to a predetermined percentage, for example 50%, which is dependent on α, the brake fluid pressure is caused to increase again. Thereafter, the above sequence of operation is repeated.
[0051] The chassis speed sensor 106 illustrated in FIG. 4 may be the conventional device adapted for installation at the front of the driver's seat. This chassis speed can be found by electrical processing of, for example, a sensor output of the rotational speed of the change-speed drive shaft. There is usually a time lag between the rotational speed of the drive shaft and the chassis speed indication value. The detected chassis speed value carrying this time lag may be utilized as it is. As an alternative, the sensor of the change-speed drive shaft speed may be provided with a signal processing system adapted to output an appropriate chassis speed delay signal to cause a delay in the chassis speed signal output and this value be fed to the control means 103 as chassis speed data. When this chassis speed falls below a predetermined value (for example, several kilometers per hour), the control means 103 is not caused to make a transition from ordinary braking action to antilbck braking action even if the brake pedal is depressed with a force over a predetermined value. When the chassis speed drops below said predetermined value during an antilock braking action, irrespective of the stage which the control means 103 is executing in the flow charts illustrated in FIGS. 5 through 7 , it immediately executes the interruption routine shown in FIG. 8 to terminate the antilock braking action and controls the brake fluid system so that the ordinary braking action resumes. If the chassis speed is very low, the need for antilock braking action is not great and this action is not required at all when the vehicle is standing still. In consideration of the above, this embodiment is so designed that the antilock braking action will not take place when the chassis speed is below a predetermined value. Since the chassis speed data referred to has a delay from the rotational speed of the drive shaft, there is no response to a sudden decrease in drive shaft rotational speed due to locking of the drive wheels upon application of the brake. Therefore, the risk of a failure to enter into an antilock braking action due to locking prior to the transition from ordinary braking to antilock braking on depression of the brake pedal is reduced. Furthermore, the risk of release of the antilock braking action and return to the ordinary braking action in the event of locking during antilock braking is eliminated.
[0052] Irrespective of the stage of the flow chart which the control means 103 is executing, the interruption routine shown in FIG. 8 is executed immediately upon generation of an antilock brake release instruction signal to terminate the antilock braking action and the ordinary braking action resumes. This action can be incorporated in the first-mentioned embodiment illustrated in FIGS. 2 and 3 . The generation timing of said antilock braking release instruction may for example be (1) when the brake pedal-depressing force has decreased below a predetermined reference value, (2) when the brake pedal is re-depressed after releasing of the depressing force, or (3) when the engine key is turned off. Of these alternatives, (2) and (3) are advantageous in that even if an accident disables the driver to manipulate the controls, the vehicle can be automatically brought to standstill with the ideal braking characteristic.
[0053] A more effective antilock brake control can be implemented by replacing the comparison at step 165 in the brake fluid recompression routine 124 with the comparison of whether the relation of μ t −μ t-1 >μ c2′ where μ c2 is a predetermined appropriate positive reference value, holds true. This reference value μ c2 preferably satisfies the condition μ C2 /Δt 2 >μ c /Δt 1 , wherein Δt 2 is the larger of the time period in which the sequence proceeds from step 143 to step 146 and to step 149 in the brake fluid decompression routine 123 and further to step 160 to step 163 in the brake fluid recompression routine 124 and the time period of the loop in which the sequence proceeds from step 163 in the brake fluid recompression routine 124 and returns through steps 165 , 167 and 162 back to step 163 , and Δt 1 is the time period of the loop in which the sequence proceeds from step 116 in the main routine through steps 118 , 119 and 113 and back to step 116 . It is also preferable that the above-mentioned brake recompression routine be interposed downstream of step 112 in the above-mentioned main routine shown in FIG. 5 . The course of return from step 119 to step 113 remains unchanged. In the above case, the reference value μ c2 in the brake fluid recompression routine 124 may be an appropriate value satisfying the relation μ c2 /Δt 2 >μ c /Δ t , wherein Δt 2 is the larger of the values of the time period in which the sequence proceeds from step 111 to step 163 in the interposed brake fluid recompression routine 124 and the time period of the loop in which the sequence proceeds from step 163 in the inserted brake fluid recompression routine through steps 165 , 167 and 162 back to step 163 .
[0054] Now, the road surface friction coefficient detector 101 embodying the principle of this invention is described below with reference to FIG. 9 through 19 .
[0055] In this embodiment, the strain in the axle or in the vicinity of the axle is measured by means of strain gauges 41 to 44 and 51 to 54 for the rear wheels and strain gauges 71 to 74 , 75 to 78 , 81 to 84 and 85 to 88 or strain gauges 41 to 44 and 51 to 54 , for the front wheels, whereby the road surface frictional force and the load in the vertical direction are detected. The strain gauge itself is a known technology utilizing the fact that the electric resistance of a resistance wire changes in proportion with strain. Typically, it comprises a rectangular film in which a resistance wire has been embedded and detects the tensile strain and compressive strain in its longitudinal direction.
[0056] An example of the position of attachment of strain gauges in the vicinity of a rear wheel 64 is shown in FIGS. 9 through 11 . It should be understood that the arrowmarks 61 , 62 and 63 indicate the vertical direction, direction of advance, and axle direction, respectively, of the wheels 64 . A total of 8 strain gauges 41 to 44 and 51 to 54 are affixed to the surface of a rear axle housing 66 between the wheel 64 and a rear spring 65 secured rigidly to a car body 58 . A set of 4 strain gauges 41 , 42 , 43 and 44 for detection of the vertical load that acts on the rear wheel 64 and another set of 4 strain gauges 51 , 52 , 53 and 54 for detection of the road surface frictional force which acts on the same wheel 64 are assembled into the respective bridge circuits as shown in FIG. 12 and the outputs of the respective bridge circuits are fed to amplifiers 45 and 55 .
[0057] As shown in FIG. 10 , the set of strain gauges 41 , 42 , 43 and 44 are affixed on the line of intersection of a horizontal plane including the axis or centerline of the rear axle housing 66 with the surface of the housing 66 for measuring the compressive and tensile strains in the direction at an angle of 45 degrees from said line of intersection. However, strain gauges 41 and 42 and strain gauges 43 and 44 are respectively disposed close to each other and the strain gauges 41 and 44 and the strain gauges 42 and 43 are respectively disposed in symmetric relation with respect to the centerline. The other set of strain gauges 51 , 52 , 53 and 54 are disposed as illustrated in FIG. 11 . Thus, they are affixed on the line of intersection of a vertical plane including the centerline of rear axle housing 66 with the surface of said housing 66 for measuring the compressive and tensile strains in the direction at an angle of 45 degrees from said line of intersection. Furthermore, the strain gauges 51 and 52 and the strain gauges 53 and 54 are respectively disposed close to each other and the strain gauges 51 and 54 and the strain gauges 52 and 53 are respectively disposed in symmetric relation with respect to the centerline.
[0058] By the vertical load acting on the wheel 64 , the rear axle housing 66 is subject to a bending deformation such that the centerline or axis of the housing 66 is bent on a vertical plane including the centerline. At the same time, a shearing force equivalent to the vertical load is applied vertically to the cross-sectional area perpendicular to the centerline of the rear axle housing 66 . In proportion with this shearing force, a shear strain is generated in the rear axle housing 66 . The bridge circuit consisting of the set of strain gauges 41 , 42 , 43 and 44 detects this shear strain. Thus, even if the above-mentioned bending deformation caused the respective strain gauges to undergo compression or elongation, the effects of the bending deformation on strain gauges 41 , 42 , 43 and 44 are mutually offset in this bridge circuit. Thus, the voltage output of the amplifier 45 is only proportional to the vertical load acting on the wheel and not subject to the effect of the moments around a rear spring 65 .
[0059] The road surface frictional force acting on the wheel 64 causes a bending deformation such that the centerline of the rear axle housing 66 is bent on a horizontal plane including the centerline. At the same time, a shearing force equivalent to the road surface frictional force is applied horizontally to the cross-sectional area perpendicular to the centerline of rear axle housing 66 . In proportion with this shearing force, a shear strain is generated in the rear axle housing 66 . The bridge circuit consisting of strain gauges 51 , 52 , 53 and 54 detects this shear strain. Just as mentioned above, the effects of the bending deformation on the respective strain gauges are mutually offset in this bridge circuit. Therefore, the voltage output of the amplifier 55 is only proportional to the road surface frictional force applied to the wheel 64 and is not subject to the influence of the moments around the rear spring 65 .
[0060] Furthermore, the bending deformation and shear strain due to the vertical load do not interfere with the output voltage of the bridge circuit consisting of strain gauges 51 through 54 constituting said one set, and the bending deformation and shear strain due to the road surface frictional force do not influence the output voltage of the bridge circuit consisting of strain gauges 41 through 44 constituting the other set. Though the cornering force (lateral drag) acting on the wheel 64 adds a compressive or tensile strain to the rear axle housing 66 in the direction of its center-line, these strains do not affect the output voltage of the bridge circuit consisting of strain gauges 41 through 44 , nor do they interfere with the voltage output of the bridge circuit consisting of strain gauges 51 through 54 .
[0061] Furthermore, as the brake is applied to the wheel 64 , the brake torque (the moment about the centerline of the axle) generates a torsional deformation in the rear axle housing 66 about its axis. However, the voltage outputs of the bridge circuits consisting of said sets of strain gauges 41 to 44 and 51 to 54 are not affected by the torsional deformation.
[0062] Furthermore, in view of the fact that the rear axle housing 66 is made of a steel material with a high thermal conductivity, the temperature difference among said strain gauges 41 through 44 or among said strain gauges 51 through 54 is so small that a change in atmospheric temperature exerts little influence on the output voltages of the respective amplifiers 45 and 55 . Thus, the influence of atmospheric temperature on detected vertical load and road surface frictional force values is almost negligible. If the peripheral surface of the rear axle housing 60 is locally treated with copper and the eight strain gauges are affixed to the treated area, the inter-gauge temperature gradient and, hence, the influence of atmospheric temperature will be effectively minimized.
[0063] The moments around the rear spring 65 which act on the rear axle housing 66 owing to the vertical load and road surface frictional force applied to the rear wheel 64 vary with the shift of the point of contact on the tire surface with the ground in the axle direction, even if the vertical load or road surface frictional force remains constant. Therefore, it is necessary to detect the very vertical load and road surface frictional force without picking up such moments. This embodiment meets the above demand.
[0064] As shown in FIG. 12 , the road surface friction coefficient detector 101 according to this embodiment feeds to an operational circuit 56 a voltage signal proportional to the vertical load as obtainable as the output of an amplifier 45 and a voltage signal proportional to the road surface frictional force as obtainable as the output of an amplifier 55 . The operational circuit 56 calculates the quotient of road surface frictional force and vertical load and outputs a voltage signal corresponding to the road surface friction coefficient μ.
[0065] It should be noted that a strain gauge (tentatively called “cross gauge”) which consists of two strain gauges disposed as intersecting each other at right angles and is capable of measuring the tensile or compressive strains in biaxial directions is commercially available. Therefore, as shown in FIG. 13 , each of the couples of strain gauges 41 and 42 ; 43 and 44 ; 51 and 52 ; and 53 and 54 may be replaced with one cross gauge to constitute bridge circuits as illustrated in FIG. 12 to accomplish the desired effect with greater efficiency. When cross gauges are used, the interval between strain gauges in each pair (for example, 41 and 42 ) become zero and the tensile or compressive strains in two perpendicular directions can be measured in one and the same position, with the result that the measurement of the vertical load and road surface frictional force can be performed with improved accuracy.
[0066] FIGS. 14 through 16 show exemplary positions of attachment of strain gauges in the vicinity of the axle of the front wheel 57 , taking as an example a front wheel suspension structure of the so-called wishbone type. In the views, the arrowmarks 61 , 47 and 48 indicate the vertical direction, direction of advance and axle direction, respectively, of the wheel 57 . The arrowmark 46 is parallel to the arrowmark 48 and points to the side on which the wheel is positioned. It is recommended that strain gauges 71 through 74 and strain gages 81 through 84 be affixed respectively on the lateral sides of two upper and lower wheel supporting members 60 and 69 for transmitting the force acting on the wheel 57 to a suspension mechanism 59 connected to the vehicle body 58 and strain gauges 75 through 78 and strain gauges 85 through 88 be affixed on the top and bottom sides, respectively. In these views, the use of aforesaid cross gauges is represented.
[0067] As shown in FIG. 15 , a set of four strain gauges 71 , 72 , 73 and 74 are affixed on both lateral sides of the lower wheel supporting member 60 in such a manner that the strain gauges 71 and 72 and the strain gauges 73 and 74 are respectively disposed in symmetric relation with each other on the respective lateral sides. These gauges are affixed at an angle of 45 degrees from the vertical direction 61 and the axle direction 48 . Quite similarly, the strain gauges 81 , 82 , 83 and 84 constituting another set are affixed on both lateral sides of the upper wheel supporting member 69 . The positions and direction of attachment are similar to those shown in FIG. 15 except that the supporting member 60 should read 69 and the strain gauges 71 , 72 , 73 and 74 read 81 , 82 , 83 and 84 , respectively.
[0068] As illustrated in FIG. 16 , strain gauges 75 , 76 , 77 and 78 forming another set are affixed on the top and bottom sides of the lower wheel supporting member 60 in such a manner that the strain gauges 75 and 76 and the strain gauges 77 and 78 are respectively disposed in symmetric relation on the respective sides. These gauges are affixed at an angle of 45 degrees from the direction of advance 47 and axle direction 48 . Quite similarly, strain gauges 85 , 86 , 87 and 88 forming another set are affixed on the top and bottom sides of the upper wheel supporting member 69 . The positions and direction of attachment are similar to those indicated in FIG. 16 except that the supporting member 60 should read 69 and the strain gauges 75 , 76 , 77 and 78 read 85 , 86 , 87 and 88 , respectively.
[0069] As it was the case with the rear wheel 64 , each set of these strain gauges 71 through 74 , 81 through 84 , 75 through 78 and 85 through 88 constitutes a bridge circuit and is connected to the corresponding one of amplifiers 91 , 92 , 93 and 94 as shown in FIG. 17 .
[0070] The vertical load acting on the wheel 57 generates a shearing force equivalent to the vertical load, as a sum of shearing forces for the upper and lower wheel supporting members 60 and 69 , in vertical direction 61 in the cross-sectional area perpendicular to the axle direction 48 of each of the supporting members 60 and 69 . As a result, shear strains proportional to the shearing forces acting on the supporting members 60 and 69 , respectively, are generated in the respective wheel supporting members 60 and 69 . The bridge circuits consisting of strain gauges 71 , 72 , 73 and 74 and strain gauges 81 , 82 , 83 and 84 , respectively, detect these respective shear strains. The outputs of amplifiers 91 and 92 representing detected values of these two shear strains are added in a predetermined suitable ratio in an operational circuit 95 shown in FIG. 17 and the result is outputted. In this manner, a voltage signal proportional to the vertical load applied to the wheel 57 is obtained as the output of said operational circuit 95 .
[0071] Similarly, the road surface frictional force applied to the wheel 57 generates a shearing force equivalent to the road surface frictional force, as the sum of forces for the upper and lower wheel supporting members 60 and 69 , in travel direction 47 in the cross-sectional area perpendicular to the axle direction 48 of each of the wheel supporting members 60 and 69 . As a result, shear strains proportional to the shearing forces acting on the supporting members 60 and 69 , respectively, are generated in the wheel supporting members 60 and 69 , respectively. The bridge circuits consisting of strain gauges 75 , 76 , 77 and 78 and strain gauges 85 , 86 , 87 and 88 , respectively, detect these shear strains, respectively. The outputs of amplifiers 93 and 94 which represent detected values of these two shear strains are added in a predetermined suitable ratio in an operational circuit 96 shown in FIG. 17 and the result is outputted. In this manner, a voltage signal proportional to the road surface frictional force acting on the wheel 57 is obtained as the output of the operational circuit 96 . The outputs of the two operational circuits 95 and 96 are fed to an operational circuit 97 which, like the operational circuit 56 shown in FIG. 12 , calculates the quotient of road surface frictional force and vertical load and outputs a voltage signal corresponding to the road surface friction coefficient μ.
[0072] As it is the case with the rear wheel 64 , the cornering force applied to the wheel does not affect detected values of vertical load and road surface frictional force. Furthermore, the vertical load does not interfere with the detected road surface frictional force value and the reverse is also true. Moreover, for the same reason as mentioned in connection with the rear wheel 64 , the influence of atmospheric temperature is also small. Similarly, too, the influence of atmospheric temperature can be further minimized by treating the surfaces of the wheel supporting members 60 and 69 with copper and affixing the strain gauges thereon. By the vertical load acting on the wheel 57 , the wheel supporting members 60 and 69 are subjected not only to the above-mentioned shearing forces but also to compressive and tensile forces in the axle direction 48 . However, as it is the case with the effect of cornering force, neither the detected value of road surface frictional force nor that of vertical load is influenced. Furthermore, by the braking torque acting as the brake for wheel 57 is applied, a shearing force is generated in the direction of advance 47 in the cross-sectional area perpendicular to the axle direction 48 of each of the wheel supporting members 60 and 69 . As a result, shear strains, proportional to the shearing forces acting on the wheel supporting members 60 and 69 are generated in the supporting members 60 and 69 . The bridge circuits consisting of strain gauges 75 , 76 , 77 and 78 and strain gauges 85 , 86 , 87 and 88 , respectively, detect these shear strains, respectively. However, as mentioned hereinbefore, the outputs of amplifiers 93 and 94 are added in a predetermined suitable ratio in the operational circuit 96 . Therefore, the effects of shearing forces due to said torque are offset and consequently a voltage signal proportional to the road surface frictional force acting on the wheel 57 is obtained as the output of said operational circuit 96 .
[0073] As will be apparent from the construction illustrated in FIG. 14 , the upper wheel supporting member does not substantially bear the vertical load on the wheel. Therefore, even if the set of strain gauges 81 through 84 , amplifier circuit 92 and operational circuit 95 are omitted and the output of the amplifier 91 is fed as the detected value of vertical load directly to the operational circuit 97 , the error will be almost negligible.
[0074] FIGS. 18 and 19 show the positions of installation of strain gauges in the front wheel 57 axle region where the suspension mechanism is the so-called “strat” type. Preferably, strain gauges 41 through 44 are affixed on the lateral sides and strain gauges 51 through 54 on the top and bottom sides of a support member 99 adapted to transmit the force acting on the wheel 57 to a strat 98 . In these views, the cross gauges mentioned above are shown by way of example. Like the above-mentioned strain gauges 71 through 74 or 81 through 84 , the strain gauges 41 through 44 are positioned in the direction at an angle of 45 degrees with respect to vertical direction 61 and in such a manner that the couple of 41 and 42 and the couple of 43 and 44 are symmetrically positioned on the lateral sides of the support member 99 . Similarly, the strain gauges 51 through 54 are affixed in the direction at an angle of 45 degrees with respect to the axle direction 48 and in such a manner that the couple of 51 and 52 and the couple of 53 and 54 are symmetrically disposed on the top and bottom sides of the support member 99 . These sets of strain gauges 41 to 44 and strain gauges 51 to 54 each constitutes a bridge as illustrated in FIG. 12 and are connected to amplifiers 45 and 55 , respectively. The respective amplifiers 45 and 55 output voltage signals proportional to the vertical load and road surface friction force acting on the wheel 57 , respectively. These voltage signals are fed to an operational circuit 56 . Just as in the case of the rear wheel 64 , the operational circuit 56 outputs a voltage signal corresponding to the road surface friction coefficient μ.
[0075] In this embodiment, as it is the case with the rear wheel 64 and the front wheel 57 having the “wishbone” suspension mechanism, the cornering force acting on the wheel does not interfere with the detected values of vertical load and road surface friction force. Moreover, the vertical load does not influence the detected value of road surface friction force and the reverse also holds true. Furthermore, the influence of variation in atmospheric temperature is also negligible. This influence of atmospheric temperature may be further diminished by treating the surface of the support member 99 locally with copper and affixing the strain gauges to the treated areas. In addition, just as it was the case with the rear wheel 64 , the vertical load acting on the wheel 57 generates not only a shear strain but a bending deformation in the support member 99 . Furthermore, when the brake is applied to the wheel 57 , the brake torque superimposes a torsional deformation in the support member 99 . However, neither the bending deformation nor the torsional deformation affects the voltage outputs of the bridge circuits consisting of said sets of strain gauges 41 to 44 and 51 to 54 . Therefore, the amplifiers 45 and 55 each outputs a voltage signal which is exclusively proportional to the vertical load and road surface friction force acting on the wheel 57 .
[0076] The road surface friction sensor 1 included in the illustration of FIG. 2 can be constituted, for the rear wheel and the front wheel connected to the strat type suspension mechanism, by the bridge circuit consisting of strain gauges 51 through 54 and amplifier 55 as shown in FIG. 12 and a voltage signal proportional to the road surface frictional force as obtainable as the output of the amplifier 55 can be directly fed to the control means 3 . For the front wheel which is connected to the “wishbone” suspension mechanism, the sensor 1 can be constituted by bridge circuits comprising two sets of strain gauges 75 through 77 and 85 through 87 , amplifiers 93 and 94 and an operational circuit 96 as shown in FIG. 17 and, then, a voltage signal proportional to the road surface frictional force as obtainable as the output of the amplifier 96 can be directly fed to the control means 3 .
[0077] When the brake is applied to the wheel 57 during the running of the vehicle in the direction of arrow-mark 67 as illustrated in FIG. 20 , the centerline AB along the lateral side of the tire of this wheel 57 is displaced, for example to AB′, according to the magnitude of the frictional force from a road surface 68 . Moreover, the tire is deformed by the vertical load so that the distance between A and B is altered. Therefore, when the lateral side of the tire is locally marked in a suitable pattern and the deformation of the marking is measured by optical means such as image pickup elements disposed in the vicinity of the wheel 57 , the strain of the tire itself can be known through the image data. Then, based on the result, the road surface frictional force and vertical load values are calculated. Using the road surface friction coefficient μ obtained by computation from the two calculated values, the antilock braking action shown in FIGS. 5 through 8 is effected. It is also possible to calculate the road surface frictional force only and perform the antilock braking action of FIG. 3 according to the result of the calculation.
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A method for cyclically controlling the braking of a vehicle includes the following steps: (a) detecting a road surface frictional force of said vehicle, (b) detecting a brake fluid pressure, and (c) controlling the brake fluid pressure in response to detected values including the brake fluid pressure and the road surface frictional force, the controlling including decreasing the brake fluid pressure in response to the road surface frictional force declining during an increase of the brake fluid pressure and increasing the brake fluid pressure in response to the road surface frictional force declining during fall-off of the brake fluid pressure.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a rotational speed sensor and particularly to one for use on a motor vehicle for detecting the rotational speed of a ground engaging wheel. The invention further relates to such sensors having temperature sensing capabilities.
In numerous environments, there is a need to measure relative rotation between elements of a machine. For example, rotation sensors are used for jet engine main shafts, machine tool spindles, etc. Another application for such sensors is for anti-lock braking systems (ABS) which are increasingly popular on present day motor vehicles. Such systems are provided to automatically prevent wheel lock-up during hard braking maneuvers so that vehicle stability and directional control can be maintained. A critical feature of an ABS is a wheel speed sensor which provides an output to an ABS controller related to wheel rotation. Many passenger cars have such a sensor for each of their four wheels. Through such inputs, the braking system controller can determine if a wheel lock-up condition has occurred or is being approached and thus control the braking system. Wheel speed sensors are also used to provide inputs for traction control systems which reduce wheel spin during acceleration.
Numerous designs of ABS wheel speed sensors are presently known. Such sensors generally consist of a rotating part (rotor) in close proximity to a stationary part (stator). The rotating part, or "tone ring", has features which can be sensed as they pass the stationary part. Such features are typically ferromagnetic teeth, as on a gear, or magnetic poles which have been applied to the part. The stationary part includes a transducer which can detect the passing of the features of the tone ring as the tone ring rotates. The detection is indicated by an electrical signal which is emitted by the transducer. The transducer may be a variable reluctance device, Hall effect device, magneto-restrictive device, or of some other construction. Generally, the transducer is a device which senses magnetic fields or changing magnetic fields. Variable reluctance transducers are referred to as "passive" sensors in that they generate a voltage without being energized by an external source. "Active" sensors such as a Hall effect device are energized by an externally applied voltage and provide an output responsive to the magnetic fields passing through them.
Although sensors utilizing the above described technologies have been implemented with success, designers of such systems are constantly striving to increase their reliability, increase output signal strength, reduce packaging space requirements, facilitate production, assembly and calibration, all the while seeking to reduce their cost. Of principal concern is protecting the sensor elements from contaminants and environmental exposure. Road debris such as dirt, dust, salt and water can interfere with an unprotected sensor. In addition, wear debris from braking surfaces and significant temperature extremes are encountered by the sensor system. A present trend in wheel speed sensor design is to integrate the sensor into a wheel bearing assembly, enabling the system to be aligned and tested prior to being shipped to the vehicle manufacturer. Moreover, such an integrated configuration simplifies vehicle assembly on the assembly line and should increase reliability.
In modern day motor vehicle design, efficiency of packaging, light weight, ease of assembly, and reliability are of paramount importance. The hub and bearing assembly of this invention provides a compact and efficient construction and integrates many of the components of the bearing into the wheel speed sensor to provide an efficiently packaged unit. Moreover, the construction of the hub and bearing of this invention provides a sealed environment for the speed sensor, isolating it from environmental factors. The efficient magnetic configuration of the assembly of this invention provides a high level electrical output even at relatively low wheel speeds as compared with other variable reluctance type transducers.
Temperatures within vehicle wheel hubs can reach extreme levels as a result of bearing failures caused by lack of lubricant or other causes of high friction. Excessive temperatures can also be generated by the braking system caused, for example, by heavy use of the vehicle brakes in panic braking situations, or constant application of braking pressure on long down grades, especially in heavy-duty vehicles. If an indication of excessive wheel hub temperature is available, a driver could take corrective action. Although temperature sensing systems are presently known, they generally require the use of a separate sensing element such as a thermocouple or thermistor.
Another facet of the present invention is to utilize the coil winding of a wheel speed sensor transducer as a temperature sensitive element. The electrical resistance of the coil varies as a function of its temperature. By monitoring the coil resistance, the temperature may be determined. Several electrical circuit configurations are described to enable such resistance measurements.
In addition to motor vehicle applications, the features of this invention are believed applicable to a broad range of applications where a measurement of relative rotation is desired and/or where temperature measurements are needed.
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiments and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded pictorial view of a hub and bearing assembly in accordance with this invention.
FIG. 2 is a partial cross-sectional view of the hub and bearing assembly of FIG. 1, shown in an assembled condition.
FIG. 3 is a frontal view of the annular transducer case shown in FIG. 2 according to a first embodiment of this invention, showing the staggered teeth arrangement formed by the transducer case.
FIG. 4 is an enlarged partial view taken from FIG. 3.
FIG. 5 is a partial pictorial view of the annular sensor shown in the prior Figures particularly showing the staggered inner and outer teeth.
FIG. 6 is a partial pictorial view of a sensor in accordance with a second embodiment of this invention featuring a transducer frame having radially aligned inner and outer teeth.
FIG. 7 is a simplified electrical circuit diagram showing a voltage divider circuit for obtaining an output voltage related to coil winding temperature.
FIG. 8 is a signal diagram for the circuit of FIG. 7 showing an AC output component related to vehicle wheel speed and a DC offset or bias related to resistance of the transducer coil winding.
FIG. 9 is a simplified electrical circuit diagram providing a constant current source approach for determining the resistance of a coil winding as affected by winding temperature.
FIG. 10 is a simplified electrical circuit diagram for processing a voltage signal containing both AC and DC components to provide separate outputs related to relative rotation and winding resistance.
FIG. 11 is a partial cross-sectional view of a hub and bearing assembly according to a third embodiment of this invention featuring an annular sensor with radially outwardly facing teeth confronting a cylindrical tone ring.
FIG. 12 is a partial cross-sectional view of a hub and bearing assembly according to a fourth embodiment of this invention featuring an annular sensor with radially inwardly facing teeth confronting a cylindrical tone ring.
DETAILED DESCRIPTION OF THE INVENTION
A hub and bearing assembly in accordance with this invention is shown in FIGS. 1 and 2 and is generally designated there by reference number 10. Hub and bearing assembly 10 as shown in the Figures is particularly adapted for use on a non-driven axle of a motor vehicle. The concepts of the present invention are, however, applicable to hub and bearing assemblies for driven axles.
Hub 14 has a radially extending flange which provides a mounting surface for a vehicle wheel (not shown). Hub 14 also defines an inside cylindrical surface 16 and a pair of roller bearing elements races including inboard race 18 and an outboard race 20. Hub 14 also has a stepped enlarged bore section 22 which, as will be explained in detail below, provides an area for mounting of a wheel rotation sensor.
Bearing inner race 26 is positioned inside hub 14 and engages a series of ball bearing elements 28 and defines the inboard bearing of the assembly. The outboard inner race is not shown in the Figures and would be of conventional construction, defining an inner surface for engagement with an outboard series of ball elements. Inner race 26 also has an inside cylindrical passageway 30 which is provided for mounting to a non-rotating spindle 32 of the vehicle. In operation, a vehicle wheel mounted to hub 14 rotates, while inner race 26 is fixed relative to spindle 32. A principle feature of hub and bearing assembly 10 in accordance with this invention is the provision of sensor 36 for the detection of wheel rotation. As previously explained, sensor 36 provides an output for control of an ABS or traction control system for a vehicle. Sensor 36 generally comprises a rotor and stator in the form of tone ring 38 and annular transducer 40, respectively. In addition to FIGS. 1 and 2, reference will be made to FIGS. 3 through 5 in a description of sensor 36.
Tone ring 38 is a permanent magnet in a disk configuration and has a radial face surface 44. A best shown in FIG. 2, tone ring 38 is carried by tone ring retainer 46 which is press-fit into hub bore 22. In an alternate design, tone ring 38 could be directly fit into hub bore 22. FIG. 5 shows that tone ring 38 defines areas of magnetic polarity arranged along radials with respect to the center of rotation of the hub bearing assembly. The polarity of tone ring 38 alternates along face surface 44 in a circumferential direction. The magnetic fields produced by the poles are oriented through radial face 44 of the tone ring. While various materials for forming tone ring can be implemented, these inventors have found that an alloy of Fe--Cr--Co can be used.
Annular transducer 40 has a case 42 in the shape of a side-opening shell, having a radial side wall 50 and a pair of cylindrical walls including inner wall 52 and outer wall 54. Walls 52 and 54 are separated to define an annular cavity 56. Both walls 52 and 54 define a plurality of extending teeth 58 and 60, respectively, arranged around their perimeter. As shown in FIG. 1, transducer cavity 56 accommodates a coil winding 62 which is wrapped within bobbin 64. Preferably, the number of teeth of each of walls 52 and 54 are equal to the number of regions of tone ring 38 which are magnetized with a particular magnetic polarity.
As shown in FIGS. 4 and 5, teeth 58 and 60 are radially staggered such that the outer set of teeth 60 are facing areas of tone ring 38 defining one magnetic pole, whereas inner teeth 52 are facing an area of tone ring 38 defining the opposite magnetic pole. As shown in FIG. 4, a radial line is shown passing between inner teeth 58 while intersecting with outer tooth 60. In the orientation shown in FIG. 5, as outer teeth 60 are facing North magnetic poles, inner teeth 58 are facing South magnetic pole regions. As tone ring 38 rotates as shown by the curved arrow, transducer teeth 58 and 60 face alternating magnetic poles. This induces a reversing magnetic field through transducer case 42. In FIG. 5, the arrows along the surface of transducer case 42 and tone ring 38 show the lines of magnetic flux for the illustrated relative orientation between transducer case 42 and tone ring 38. However, upon relative rotation of tone ring 38, the flux field reverses in direction. This reversing magnetic flux field through annular transducer case 42 induces an emf (voltage) within coil winding 62.
The configuration of annular transducer 40 provides excellent electrical output since each of the inner and outer sets of teeth 58 and 60 magnetically engage with all of the magnetized regions of tone ring 58 upon relative rotation. Therefore, most of the magnetic flux from the entire tone ring 58 participates in developing an emf within coil winding 62.
Annular transducer 40 is fixed relative to inner race 26, preferably through press-fitting it onto an external cylindrical surface of inner race 26 as shown in FIG. 2. The bearing rolling ball elements 28 and sensor 36 are protected by seal 68. Seal 68 has a retainer ring 70 which is press-fit onto hub 14 and mounts an elastic lip 72 which contacts transducer case 42. Since transducer 40 is oriented such that the open portion of case 42 is facing ball elements 28, the radial side surface 50, and walls 52 and 54, combine to enclose and protect the bearing elements. This configuration also has the advantage that sensor 36 is readily accessible for service or replacement.
FIG. 6 illustrates an alternate embodiment of a sensor in accordance with this invention which is designated by reference number 80. Tone ring 82 shown in FIG. 6 defines areas of magnetic polarity which alternate not only in a circumferential direction along its radial face as in the case of tone ring 38, but also alternate in a radial direction. With this configuration, the inner and outer transducer case teeth 84 and 86, respectively, of case 88 are oriented along radials with respect to the axis of rotation of the hub and bearing assembly. With this orientation, the same magnetic conditions exists as in the first embodiment in that the outer set of teeth 86 are exposed to magnetic poles of one polarity at the same time that the inner set of teeth 84 are exposed to the opposite polarity magnetic pole. In other respects, sensor 80 would operate in a manner like that of sensor 36.
In addition to a novel hub and bearing assembly and sensor design, this invention also encompasses a manner of indirectly measuring temperature of the hub and bearing assembly through a measurement of the temperature of coil winding 62. The ability to sense temperature can be critical in order to prevent heat related failures, such as that resulting from excessive or faulty braking from occurring. In accordance with this invention, temperature sensing is provided without adding any elements to the hub and bearing assembly 10. The feature is provided through the use of circuity which provides an accurate measure of the resistance of coil winding 62. The DC resistance of an electrical conductor such as copper has a linear (or near linear) relationship to temperature such that the resistance of the element at any given temperature can be calculated using a simple formula.
This formula is simply the coefficient of temperature of the conductor multiplied by the resistance of the conductor at room temperature. This value is a change of resistance for each degree change in temperature. In order to obtain the resistance at a desired temperature, the delta resistance is multiplied by the total change in temperature and added to or subtracted from the conductor resistance at room temperature. With this ability to know what the resistance values are with respect to temperature of coil winding 62, a circuit can be utilized to process this into useable information.
In the typical implementation of a variable reluctance transducer including those previously described, one end of the coil winding is tied to electrical ground. In this configuration, wheel rotation produces an AC signal which is centered about ground (i.e. zero bias voltage). In order to exploit the combined temperature responsive characteristics of the winding along with rotation sensing, various approaches can be taken. One technique is illustrated by the circuit diagram of FIG. 7, designated by reference number 90. Circuit 90 is a simple voltage divider network. For this circuit a regulated voltage is provided using voltage regulator 92 connected to the vehicle battery power source 94. The regulated voltage output is applied to a pair of resistors in series, with resistor 96 acting as a reference resistor, whereas coil winding 62 defines a variable resistor whose resistance is related to temperature. The voltage at sensing node 98 provides a means of measuring the resistance of coil winding 62. If there is no relative rotation between the transducer stator and rotor, the voltage output measured at sensing node 98 will correspond with a particular resistance and hence temperature of coil winding 62. During rotation of tone ring 38 relative to transducer 40, an alternating AC signal will be observed at sensing node 98 with a DC bias which is proportional to resistance and, therefore, temperature of coil winding 62.
FIG. 8 provides a trace of a representative signal measured at node 98 in which the DC offset 102 provides the temperature measuring value whereas the frequency of the AC trace 104 is related to rotational speed. The particular value of DC bias 102 would be dependent upon the characteristics of the coil winding, including the length of conductor used, its gauge and material, along with the chosen value of the regulated voltage source and the relative resistance values of reference resistor 96 and coil winding 62.
The temperature measurement principles of this invention could be used with a broad array of materials defining coil winding 62 which exhibit a temperature resistance coefficient, whether it be a negative coefficient as in the case of metals or a positive coefficient as found in some semi-conductors. Naturally, a calibration table or curve would have to be created for the material and configuration selected for coil winding 62.
Another circuit for providing a resistance measurement for coil winding 62 is illustrated in FIG. 9 and is designated there by reference number 110. In this configuration, transistor 112 and resistor 114 provide a source of constant current through coil winding 62. In this case, the voltage at sensing node 116 also varies as the resistance of coil winding 62 changes in accordance with Ohm's law. As the resistance of coil winding 62 changes so does the voltage across the winding measured at node 116. As in the case of circuit 90, upon relative rotation between the tone ring 38 and transducer 40, an AC signal with a DC bias will be observed at sensing node 116.
As is evident from a description of the circuits 90 and 110, the voltage at the sensing nodes is sensitive to loading. This results in the requirement that any outside circuit used to measure and evaluate the waveform must have a high impedance input. An example of one such a circuit is provided in FIG. 10 and is generally designated by reference number 120. Circuit 120 could be used with either of the prior approaches for providing a voltage output related to wheel rotation and resistance of the coil winding. In circuit 120, op-amp 122 is provided for input loading isolation. Op-amps available today are inherently high input impedance devices. Op-amp 122 includes a feedback loop including a voltage divider network including resistors 124 and 126 which provide a feedback voltage for gain control of op-amp 122. The output signal of op-amp 122 contains both an AC component related to wheel rotation and a DC offset or bias related the resistance of coil winding 62.
Circuit 120 provides a pair of filter circuits designed to provide a square wave output having a frequency related to wheel speed, and a separate DC voltage for enabling temperature sensing. The network for providing a square wave output is designated by reference 128. Network 128 includes op-amp 130 with inputs of the op-amp passing through resistors 132 and 134. One of the inputs of op-amp 130 is, however, grounded through capacitor 136 which acts as an AC filter. By combining the inputs to op-amp 130 in this manner, a square wave output is provided at the output terminal of op-amp 130. The square wave output would be used by appropriate signal conditioning and controlling circuits as part of an ABS or traction control system.
Network 138 is provided as a DC pass filter in which an LC tank circuit is fed through resistor 140 and inductor 142. The tank circuit also includes inductor 144 and resistor 146 with capacitors 148 and 150 tied to chassis ground. Circuit 138 effectively removes the AC component from the output signal and provides a steady DC voltage proportional to coil winding resistance, and consequently its temperature.
FIGS. 11 and 12 provide illustrations of still additional embodiments of an annular sensor in accordance with the present invention. FIG. 11 provides a partial cross-sectional view showing sensor 160. Sensor 160 is shown installed within a hub and bearing assembly like that illustrated in FIG. 2, and accordingly, common elements are identified by like reference numbers. As shown, sensor 160 incorporates annular transducer 162 and tone ring 164 which are positioned between inboard race 18 and outboard race 20 and between bearing inner race 26 and the bearing outer race as defined by hub 14. Sensor 160 varies from the previous embodiment in that transducer case 166 defines separated rows of teeth 168 and 170 which are oriented in a radially outward direction, with respect to the axis of rotation of the hub. This embodiment of annular transducer 160 is preferably implemented in a hub and bearing assembly in which hub 14 rotates with respect to inner race 26. As with the prior embodiments, transducer case 166 is formed having an open shell cross-sectional configuration, which encloses winding 172. For this embodiment, tone ring 164 is in the shape of a cylindrical hoop which, like the prior embodiments, features areas of magnetic polarity which alternate circumferentially around the ring. For this embodiment, teeth 168 and 170 would be staggered as in the first embodiment so that at any given time, one set of teeth face one magnetic pole, whereas the other set of teeth face the opposite magnetic pole. As previously described, relative rotation of the elements produces an alternating magnetic field through case 166, thus inducing an EMF in winding 172.
FIG. 12 illustrates a fourth embodiment of a sensor according to this invention identified by reference number 180. Sensor 180 is very similar to sensor 160 except that annular transducer 182 has a case 184 defining separated rows of teeth 186 and 188 which face in a radially inward direction. As in the prior embodiments, case 184 defines an open shell cross-sectional configuration which accommodates winding 190. For this embodiment, tone ring 192 would be essentially identical to tone ring 164 shown in FIG. 11, except that it would have a smaller diameter for fitting against bearing inner race 26.
The embodiments of this invention shown in FIGS. 11 and 12 posses certain attributes as compared with the other described embodiments. The positioning of the sensors 160 and 180 between ball elements 28 renders them essentially tamper proof. Moreover, these configurations are believed to enable an enhanced degree of control over the gap defined between the tone rings 164 and 192 and their respective annular transducers 162 and 182 Better control over this gap allows smaller gaps to be provided which generates higher outputs for the sensors without allowing the tone ring and annular transducer to physically contact one another.
While the above description constitutes the preferred embodiments of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.
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A bearing assembly incorporating a speed and/or temperature sensor particularly adapted for motor vehicle wheel applications. The sensor incorporates a magnetized tone ring defining a radial or cylindrical face which interacts with an annular transducer. The transducer has a plurality of teeth facing the magnetized tone ring with separate first and second rows of teeth extending from the transducer frame. The first set of teeth engage one area of the tone ring defining one magnetic pole whereas the second series of teeth interact with regions of the tone ring defining the opposite magnetic pole. Relative rotation between the transducer and tone ring induces an alternating magnetic field through the transducer case which induces an alternating voltage in the winding coil. The transducer is efficiently packaged within the enclosed cavity of a bearing assembly. This invention further contemplates a means to allow transducer temperature to be evaluated by monitoring the DC resistance of the transducer winding.
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CLAIM OF PRIORITY
[0001] This application claims the priority under 35 U.S.C. §119(a) to an earlier Korean Application Serial No. 10-2012-0074386, which was filed in the Korean Intellectual Property Office on Jul. 9, 2012, the entire content of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates a portable terminal, and more particularly, to a portable terminal with a side key that is convenient to assemble.
[0004] 2. Description of the Related Art
[0005] A portable terminal provides a variety of services including voice communication or short message transmission, a data communication function, such as Internet, mobile banking, or multimedia file transmission, and a multimedia function, such as game or reproduction of music or a moving picture while the user is carrying the portable terminal
[0006] A portable terminal typically includes a keypad and a microphone as input devices, and a display device and a speaker as output devices. Recently, as a touch screen function is implemented as an input unit, a physical keypad is no longer available. However, a power key, a two-way key for volume tuning, a camera shutter key, etc. are still implemented using physical keys on a side of the touch screen devices.
[0007] FIG. 1 illustrates a part of a conventional portable terminal 100 including side keys. As shown, a side key installed in the conventional portable terminal 100 includes a key member 113 a or 113 b inserted into a slot formed in a housing 101 and a board 115 a or 115 b. The board 115 a or 115 b is arranged in the inside of the key member 113 a or 113 b, and a dome switch (not illustrated) is provided on the board 115 a or 115 b. The board 115 a or 115 b is typically a flexible printed circuit board and connected to a main circuit board 111 installed within the housing 101 .
[0008] The above side keys are configured such that the boards 115 a and 115 b and the key members 113 a and 113 b are independently assembled. However, there is a problem in that the key members 113 a and 113 b easily break out from the housing 101 during the assembly process. Some products employ an adhesive member for temporarily fixing the housing 101 and the key members 113 a and 113 b, for example, a vinyl tape, in order to prevent the key members 113 a and 113 b from breaking out from the housing 101 during fabrication. However, this has drawbacks in that material costs and working time are undesirably increased.
[0009] As another method for preventing breaking-out of the key members 113 a and 113 b, a flexible silicon member is dual injection-molded to the key members 113 a and 113 b, and the silicon member is fixed to the housing 101 by a separate structure. However, there are disadvantages in that it requires an extra process for dual injection-molding the silicon member, and also it is complicated to assemble the key members with a separate structure. Furthermore, a process for fixing the silicon member to the housing, for example, an ultrasonic welding has to be added, thus generating an extra fabrication step and costs.
SUMMARY OF THE INVENTION
[0010] Accordingly, an aspect of the present invention is to solve at least the above-described problems occurring in the prior art, and to provide at least the advantages described below.
[0011] Another aspect of the present invention is to provide a portable terminal configured such that a side key can be easily assembled.
[0012] Also, another aspect of the present invention is to provide a portable terminal configured to be capable of preventing a key member of a side key from breaking out from a housing during the assembly process while allowing easy assembling of the side key.
[0013] Still another aspect of the present invention is to provide a portable terminal having a side key configured to lower the material costs, and also easy and convenient to assemble, thereby contributing an increase in the productivity.
[0014] In accordance with another aspect of the present invention, a portable terminal includes: a housing; a key member movably coupled to the housing and disposed on a side of the housing; and a board arranged to be opposed to the inner surface of the key member. The board is coupled to the housing and serves to restrain the key member within the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other aspects, features, and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0016] FIG. 1 is an exploded perspective view illustrating a part of a conventional portable terminal including side keys.
[0017] FIG. 2 is a perspective view illustrating a part of a portable terminal according to an exemplary embodiment of the present invention.
[0018] FIG. 3 is a partially cutaway view illustrating a side key arranged on one side of a housing among the side keys of the portable terminal depicted in FIG. 2 ;
[0019] FIG. 4 is a perspective view illustrating the key member of the side key depicted in FIG. 3 ;
[0020] FIG. 5 is a perspective view illustrating the board of the side key depicted in FIG. 3 ;
[0021] FIG. 6 is a partially cutaway view illustrating a key member arranged on the other side of the housing among the side keys of the portable terminal depicted in FIG. 2 ;
[0022] FIG. 7 is a perspective view illustrating the key member of the side key depicted in FIG. 6 ; and
[0023] FIG. 8 is a perspective view illustrating the board of the side key depicted in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. For the purposes of clarity and simplicity, a detailed description of known functions and configurations incorporated herein will be omitted as it may make the subject matter of the present invention unclear.
[0025] FIG. 2 is a perspective view illustrating a part of a portable terminal according to an exemplary embodiment of the present invention. As shown, the portable terminal 200 includes side keys installed on the sides of a housing 201 , in which each of the side keys may include one switch member or one pair of switch members 233 a or 233 b (shown in FIGS. 5 and 8 ). In the configuration illustrated in FIG. 2 , a first side key arranged on one side of the housing 201 includes one pair of switch members 233 a (shown in FIG. 5 ), and a second side key arranged on the other side includes one switch member 233 b (shown in FIG. 8 ).
[0026] The housing 201 accommodates a main circuit board 211 inside thereof and includes slots configured to install the side keys thereto. Such a “slot” is generally formed in a form of an opening. However, in an exemplary embodiment of the present invention, support ribs 212 a and 212 b are formed on the opposed inner side walls of the housing 201 such that spaces between the inner side walls of the housing 201 and the support ribs 212 a and 212 b are used as the slots. That is, the side keys are disposed between the inner side walls of the housing 201 and the support ribs 212 a and 212 b, respectively.
[0027] FIGS. 3 and 6 illustrate the side keys installed in the housing 201 in partially cutaway views, respectively, FIGS. 4 and 7 illustrate the key members 213 a and 213 b of the side keys, respectively, and FIGS. 5 and 8 illustrate the boards 215 a and 215 b of the side keys, respectively.
[0028] Referring to FIGS. 3 and 6 , the key members 213 a and 213 b are configured to be directly manipulated by a user, and when arranged in the housing 201 , to be exposed to the outside of the housing 201 on the outer surfaces thereof Each of the key members 213 a and 213 b is formed with actuation studs 223 a or 223 b on the inner surface thereof.
[0029] Referring to FIG. 4 , the key member 213 a of the first key (hereinafter, referred to as a “first key member”) is formed with a pair of actuation studs 223 a , and the key member 213 b of the first key (hereinafter, referred to as a “first key member”) is formed with a pair of actuation studs 223 b. The first key member 213 a formed with the pair of actuation studs 223 a is adapted to conduct functions, such as a volume tuning, a screen brightness adjustment, and a menu shift.
[0030] Referring to FIG. 7 , the second key member 213 b formed with one actuation stud 223 b is used as a hot key for conducting specific functions, such as a power ON/OFF function, a camera mode activation, and a shutter function. Of course, the first key member 213 a may also be provided with such hot key functions. For example, a current time notification function, a screen locking and unlocking function or the like may be provided. This is determined by properly selecting signals assigned by a designer to each of the switch members when designing a practical product, thus any combination of actuation studs can be designated to the respective key member.
[0031] Meanwhile, referring to FIGS. 4 and 7 , at an inner edge of each of the key members 213 a and 213 b a support piece 221 a or 221 b may be formed. The support pieces 221 a and 221 b are supported by the inner surfaces of the housing 201 to prevent the key members 213 a, 213 b from breaking out to the outside of the housing 201 . As such, the key members 213 a and 213 b are arranged between the inner wall of the housing 201 and the support ribs 212 a and 212 b in such a manner that they can be prevented from being completely penetrated into the outside of the housing 201 or breaking out to the outside of the housing 201 . That is, the key members 213 a and 213 b are movable on the housing 201 within a limited range.
[0032] Referring to FIGS. 5 and 8 , the boards 215 a and 215 b are preferably formed as substantially flexible printed circuit boards. Because the flexible printed circuit boards are relatively freely deformable in shape, the boards 215 a and 215 b may be easily arranged in the slots, i.e. between the inner wall of the housing 201 and the support ribs 211 a and 211 b. Each of the boards 215 a and 215 b is arranged between the inner surface of one of the key members 213 a and 213 b and the support ribs 212 a and 212 b. The switch members 233 a and 233 b are arranged on the boards 215 a and 215 b to be opposed to the inner surfaces of the key member 213 a and 213 b, more specifically, the actuation studs 223 a and 223 b, respectively.
[0033] Accordingly, when the user pushes the key members 213 a and 213 b, the corresponding switch members 233 a and 233 b are actuated to produce a signal. Here, tact switches or dome switches are frequently used as the switch members 233 a and 233 b. However, in the exemplary embodiment of the present invention, because the boards 215 a and 215 b are arranged in the narrow spaces between the inner surfaces of the key members 213 a and 213 b and the support ribs 212 a and 212 b, dome switches, which are relatively thin, may be preferably used as the switch members 233 a and 233 b. Each of the boards 215 a and 215 b includes an operation section board 231 a or 231 b where the switches 233 a or the switch 233 b are arranged, and a connection section board 237 a or 237 b from the operation section board 231 a or 231 b, in which the operation section boards 231 a and 231 b are arranged to be opposed to the inner walls of the slots, more specifically, the support ribs 212 a and 212 b, respectively, and the connection section boards 237 a and 237 b are fixed to the main circuit board 211 . The connection section boards 237 a and 237 b may be completely fixed to the main circuit board 211 by a soldering type, and in some exemplary embodiments, may be fixed to the circuit board 211 by a connector type.
[0034] Meanwhile, referring to FIGS. 4 and 7 , in order to prevent the key members 213 a and 213 b from breaking out in a direction opposite to the insertion direction of the key members 213 a and 213 b into the slots in the state where the key members 213 a and 213 b are inserted into the slots, each of the side keys includes a restraint protrusion 225 a or 225 b and a notch 235 a or 235 b. The restraint protrusions 225 a and 225 b protrude from edges of the inner surfaces of the key members 213 a and 213 b, respectively, in which when the key members 213 a and 213 b are arranged on the housing 201 , the restraint protrusions 225 a and 225 b are positioned to be directed to the inside of the housing 201 . In the first key member 213 a, on which the pair of actuation studs 223 a and 223 b are formed, it is preferred that the restraint protrusion 225 a is formed at an edge of the inner surface of the first key member 213 a between the actuation studs 223 a and 223 b . Each of the notches 235 a and 235 b is formed on one of the boards 215 a and 215 b , more specifically, at an edge of one of the operation section boards 231 a and 231 b . Each of the notches 235 a and 235 b are formed in one of the boards 215 a and 215 b, more specifically at an edge of one of the operation section boards 231 a and 231 b to positionally correspond to one of the restraint protrusions 225 a and 225 b. As such, when the key members 213 a and 213 b and the boards 215 a and 215 b are arranged in the slots, respectively, the notches 235 a and 235 b will accommodate or receive the restraint protrusions 225 a and 225 b, respectively.
[0035] The restraint protrusions 225 a and 225 b and the notches 235 a and 235 b are structures for preventing the key members 213 a and 213 b from breaking out in the process of the portable terminal 200 . Accordingly, it is preferred that the restraint protrusions 225 a and 225 b are arranged close to the bottoms of the slots when they are arranged in the slots. If the restraint protrusions 225 a and 225 b are arranged close to the bottoms of the slots, the restraint protrusions 225 a and 225 b are surrounded by the notches 235 a and 235 b and the bottoms of the slots when the boards 215 a and 215 b are arranged in the slots. As such, the key members 213 a and 213 b are restrained in the slots by the boards 215 a and 215 b , respectively.
[0036] Meanwhile, when the key members 213 a and 213 b are required to be replaced due to damage or the like, only a key member to be replaced can be removed from the correspond slot. In the process of removing the key member from the corresponding slot, the corresponding board 215 a or 215 b is also removed from the corresponding slot. This is because the restraint protrusions 225 a and 225 b move the boards 215 a and 215 b in the directions of breaking out from the slots while the key members 213 a and 213 b are breaking out from the slots. In that event, if the boards 215 a and 215 b are interfered with another structure or fastened to the insides of the slots, the boards 215 a and 215 b may be damaged by the restraint protrusions 225 a and 225 b. In order to prevent the damage of the boards 215 a and 215 b, reinforcement members 239 a and 239 b may be attached to the boards 215 a and 215 b. It is preferred that the reinforcement members 239 a and 239 b are attached to both sides of the boards 215 a and 215 b around the notches 235 a and 235 b, specifically, while wrapping the inner walls of the notches 235 a and 235 b opposed to the restraint protrusions 225 a and 225 b , more specifically, while wrapping the inner walls of the notches 235 a and 235 b directly interfered with the restraint protrusions 225 a and 225 b while the key members are breaking out. Here, a transparent tape, a metal foil, for example, an aluminum foil or a copper foil, may be used as such a reinforcement member.
[0037] Having thus described a preferred embodiment as above, it should be apparent to those skilled in the art that certain advantages have been achieved. In particular, the portable terminal having the side keys as described above may prevent the key members from breaking out from the housing merely by arranging the key members of the side keys in the slots formed in the housing and then assembling the boards corresponding to the key members to the slots. Accordingly, the side keys can be easily installed in the narrow spaces in the portable terminal, and the decreasing of productivity due to the breaking-out of the key members in the process of assembling can be prevented. Moreover, because no separate assemble configuration or process is added or required as in the prior art which in turn reduces the assembling sequence, the present invention can improve assemblability and productivity while lowering the manufacturing costs.
[0038] While the present invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.
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A portable terminal includes a housing, a key member movably coupled to the housing and exposed to a side of the housing, and a board arranged to be opposed to the inner surface of the key member. The board is coupled to the housing and serves to restrain the key member within the housing, so that the key member is prevented from breaking out from the housing during the assembly process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an endoscope apparatus, more particularly, a constitution used in medical fields for forming and displaying a spectral image (video) made up of image information of arbitrarily selected wavelength ranges.
2. Description of the Related Art
Recently, in an electronic endoscope apparatus which uses a solid imaging device, spectral imaging combined with a narrow band pass filter on the basis of a spectral reflectance in the alimentary canal (gastric mucosa and the like), namely, a narrow band filter built-in an electronic endoscope apparatus (Narrow Band Imaging-NBI) has become the focus of attention. In place of rotational filters of R (red), G (green) and B (blue) by a frame sequential method, this system is provided with band pass filters of three narrow bands (wavelengths), outputs sequentially illumination light via these narrow bandpass filters, and conducts processing the same as in the case of red (R), green (G) and blue (B) signals while changing respective weightings to three signals obtained from these illumination lights, thereby forming a spectral image. This spectral image is able to realize microstructures and the like in gastrointestinal tracts such as the stomach and large intestine, which would otherwise not be realized.
In contrast, unlike the frame sequential method using the above-described narrow band pass filters, as described in Japanese Published Unexamined Patent Application No. 2003-93336, it has been proposed that in the simultaneous method in which micro-mosaic color filters are arranged on a solid imaging device, a spectral image is formed by the computing process on the basis of image signals obtained from white light. In this method, the relationship between numeric data of the respective R, G, and B color sensitivity characteristics and numeric data of spectral characteristics of a specific narrow bandpass is determined as matrix data (coefficient sets) and computing is made for the matrix data and the R, G and B signals to obtain spectral image signals artificially via the narrow bandpass filters. Where a spectral image is formed by such computing, it is not necessary to provide a plurality of filters corresponding to desired wavelength ranges and to provide these change-over arrangements, there by successfully avoiding increases in the size of a system and reducing cost.
However, since each wave range of the signals constituting a spectral image is a narrow band on formation of the spectral image in the endoscope apparatus, the image is reduced in brightness as compared with an ordinary image formed by RGB signals, which is a problem. FIG. 5 shows spectral sensitivity characteristics of color filters such as R (red), G (green) and B (blue) used in an elementary color-type CCD, a solid imaging device, and an example of individual wavelength ranges forming the spectral image in the present invention. As shown in this drawing, the spectral image is constituted with signals made up of, for example, wave range λ 1 (narrow band centered at 500 nm), wave range λ 2 (narrow band centered at 620 nm) and wave range λ 3 (narrow band centered at 650 nm) These wavelength ranges of λ 1 , λ 2 and λ 3 are reduced, as compared with a RGB wave range, and they are a narrow band. Therefore, all signal components in the wavelength ranges of λ 1 , λ 2 and λ 3 are extremely reduced, as compared with all signal components in the RGB wave range, and lacking in brightness components.
Further, in formation of an ordinary image, output signals of a CCD are amplified to result in an increase in noise components, and therefore the noise components of the image signal are also removed. In formation of a spectral image as well, care must be taken so as not to increase noise components when signals of individual wavelength ranges are amplified.
In addition, in a spectral image which has become the focus of attention, microstructures and others can be visualized, which has not conventionally been obtained. If specified microstructures are displayed so as to be remarkably distinguished from other tissues, valuable information on an object to be observed can be provided useful for making a diagnosis and others.
SUMMARY OF THE INVENTION
The present invention has been made in view of the problem, an object of the present invention is to provide an endoscope apparatus capable of preventing a reduction in brightness due to wavelength ranges of a narrow band, suppressing an increase in noise components and also providing valuable information on an object to be observed in which specified microstructures are extracted.
In order to attain the above-described object, an endoscope apparatus according to the first aspect of the invention comprises: an endoscope comprising an imaging device (at its distal end) that forms a color image signal of a body to be observed; a storage portion that stores matrix data (coefficient data) for forming a spectral image based on the color image signal; a spectral image-forming circuit that conducts matrix calculation based on the color image signal by using the matrix data of the storage portion and forms at least one spectral image signal each of which corresponds to an arbitrarily selected wavelength range; and an amplifier circuit that amplifies said at least one spectral image signal formed by the spectral image-forming circuit.
According to the second aspect of the invention, there is provided the endoscope apparatus, wherein said at least one spectral image signal comprises a plurality of spectral image signals corresponding to a plurality of wavelength ranges, and the amplifier circuit amplifies said plurality of image signals at individual different gains (individual different amplification rates).
According to the third aspect of the invention, there is provided the endoscope apparatus, wherein the color image signal from the imaging device is selectably: (i) passed through the spectral image-forming circuit to form said at least one spectral image signal; or (ii) not passed through the spectral image-forming circuit to form an ordinary color image signal for an ordinary display, and wherein the endoscope apparatus further comprises a noise removal circuit for removing noise of the ordinary color image signal or said at least one spectral image signal, and the noise removal circuit conducts noise processing for said at least one spectral image signal at a first noise removal rate and conducts noise processing for the ordinary color image signal at a second noise removal rate, the first noise removal rate being higher than the second noise removal rate.
According to the fourth aspect of the invention, there is provided the endoscope apparatus, wherein the noise removal circuit increases the first noise removal rate as a gain of the amplifier circuit increases, and the noise removal circuit decreases the first noise removal rate as a gain of the amplifier circuit decreases.
According to the fifth aspect of the invention, there is provided the endoscope apparatus, wherein the color image signal input to the spectral image-forming circuit is: (i) obtained by releasing gamma correction in a signal processing circuit at a front stage of the spectral image-forming circuit; or (ii) obtained via a reverse gamma-correction processing circuit, and wherein the spectral image-forming circuit forms said at least one spectral image signal based on the color image signal to which no gamma correction is given, and then gamma correction is provided to said at least one spectral image signal.
In the above-described constitution, matrix data (coefficient sets) for determining λ 1 , λ 2 and λ 3 signals which are a narrow-band wavelength (component) from RGB signals are stored in the operation memory of a processor unit. When an operator selects three wavelength ranges (one wave range may be selected) for forming a spectral image, matrix data corresponding to the three wavelength ranges are read from the memory, and λ 1 , λ 2 and λ 3 signals are formed from RGB signals output from the matrix data, a DSP and others. Thereafter, these λ 1 , λ 2 and λ 3 signals are amplified by an amplifier circuit to a predetermined gain, thereby increasing brightness up to the level as with formation of an ordinary image. Therefore, a spectral image in combination with selected three wavelength ranges is displayed on a monitor in a desired brightness.
With the constitution according to the second aspect, wavelength ranges of λ 1 , λ 2 and λ 3 capable of extracting specific microstructures, for example, blood vessels, are selected, and, of these ranges, the gain of λ 3 signal (for example, red color zone) is amplified 1.2 times that of λ 1 or λ 2 signal, thereby making it possible to form and display an image at which specific blood vessel structures are highlighted. Further, as described above, where λ 1 , λ 2 and λ 3 signals are amplified, noise components are also amplified, resulting in deterioration in image quality. Therefore, in the constitution according to the third aspect, a noise removal circuit is provided to conduct noise processing at a higher noise removal rate than that of the noise processing for forming color image signals for an ordinary display. For example, the number of frame images for comparing noise processing (equation) can be increased to elevate the noise removal rate (effect).
Further, in forming color image signals at an endoscope apparatus, gamma correction is conducted so that image signals to be input to an indicator are proportionally related to the image brightness at the indicator. In the gamma correction, underlying image signals are deformed and therefore not appropriate as an image signal for forming the spectral image. Then, in the constitution according to the fifth aspect, gamma-correction processing of the DSP and others in the previous stage is released or a reverse gamma-correction processing circuit is provided to return gamma correction to an original state, thereby forming a spectral image on the basis of color image signals to which no gamma correction is given.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the constitution of the spectral image-forming circuit of the endoscope apparatus according to an embodiment of the present invention;
FIG. 2 is a block diagram showing the constitution of the endoscope apparatus according to the embodiment;
FIG. 3 is a diagram showing the operation and the constitution inside the noise removal circuit;
FIG. 4 is a graph chart showing characteristics of the reverse gamma correction and the gamma correction according to the embodiment;
FIG. 5 is a graph chart showing an example of the wave range of a spectral image formed in the embodiment, together with spectral sensitivity characteristics of an elementary color-type CCD; and
FIG. 6 is a graph chart showing an example of the wave range of a spectral image formed in the embodiment, together with the reflection spectrum of a body.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 and FIG. 2 show a constitution of the electronic endoscope apparatus according to an embodiment in the present invention. As shown in FIG. 2 , the electronic endoscope apparatus is constituted in such a manner that a scope (electronic endoscope) 10 is connected to a processor unit 12 in a freely attachable and detachable way and a light source 14 is arranged in the processor unit 12 . Further, there is a case where the light source 14 may be arranged on a light source unit, which is a separate body. The scope 10 is provided on the end with a CCD 15 which is a solid imaging device, and the CCD 15 includes, for example, a complementary color-type CCD having color filters of Mg (magenta), Ye (yellow), Cy (cyan) and G (green) and an elementary color-type CCD having R, G and B color filters on an imaging surface.
The CCD 15 is provided with a CCD driving circuit 16 for forming a driving pulse on the basis of synchronizing signals, a CDS/AGC (correlated dual sampling/automatic gain control) circuit 17 for sampling and amplifying an image (video) signal input from the CCD 15 the image signal and an A/D converter 18 . Also arranged is a microcomputer 20 of or controlling various circuits inside the scope 10 and also controlling communications with the processor unit 12 . Further, the scope 10 is provided at the end with an illumination window 23 , which is connected to the light source 14 by a light guide 24 .
The processor unit 12 is provided with a DSP (digital signal processor) 25 which imparts a variety of image processings to digitally converted image signals. In the DSP 25 , Y/C signals constituted by a brightness (Y) signal and a color difference [C(R−Y, B−Y)] signal are formed and output from the output signal of the above-described CCD 15 . In the embodiment, ordinary images (moving image and still image) and spectral images (moving image and still image) can be selectively formed and displayed, and the DSP 25 is provided with a noise removal (noise reduction) circuit 27 for removing noise of the image signal input from the DSP 25 via a selector 26 a . Further, a spectral image-forming circuit 28 is connected via the selector 26 b for selectively forming an ordinary image or a spectral image (to one terminal). Arranged on the other terminal of the selector 26 b are a mirror image-processing circuit 29 for inverting a mirror image, a mask generating circuit 30 for generating a mask covering the periphery of the image on the indicator screen, a character generating circuit 31 for generating characters indicating operating conditions, information on patients and others, and a D/A converter 32 .
Also provided is a microcomputer 35 which controls the respective circuits inside the processor unit 12 and reads matrix (coefficient) data from a memory 36 (corresponding to the storage portion) to impart the data to the spectral image-forming circuit 28 . Matrix data (table) for forming a spectral image on the basis of RGB signals are stored in the memory 36 .
FIG. 1 shows details inside the spectral image-forming circuit 28 . The spectral image-forming circuit 28 is provided with a reverse gamma processing circuit for conducting reverse gamma (γ) correction ( FIG. 4 ), a first color conversion circuit 43 for converting brightness (Y)/color difference (C) signals to RGB signals and a color-space conversion processing circuit 44 for conducting matrix calculation for a spectral image in relation to the RGB signals. The color-space conversion processing circuit 44 outputs selected spectral image signals of λ 1 , λ 2 and λ 3 wavelength ranges.
Table 1 shows the matrix data used for conducting matrix calculation in the color-space conversion processing circuit 44 and accommodated in the memory 36 .
TABLE 1
Parameter
k pr
k pg
k pb
p1
0.000083
−0.00188
0.003592
.
.
.
.
.
.
.
.
.
.
.
.
p18
−0.00115
0.000569
0.003325
p19
−0.00118
0.001149
0.002771
p20
−0.00118
0.001731
0.0022
p21
−0.00119
0.002346
0.0016
p22
−0.00119
0.00298
0.000983
p23
−0.00119
0.003633
0.000352
.
.
.
.
.
.
.
.
.
.
.
.
p43
0.003236
0.001377
−0.00159
p44
0.003656
0.000671
−0.00126
p45
0.004022
0.000068
−0.00097
p46
0.004342
−0.00046
−0.00073
p47
0.00459
−0.00088
−0.00051
p48
0.004779
−0.00121
−0.00034
p49
0.004922
−0.00148
−0.00018
p50
0.005048
−0.00172
−3.6E−05
p51
0.005152
−0.00192
0.000088
p52
0.005215
−0.00207
0.000217
.
.
.
.
.
.
.
.
.
.
.
.
p61
0.00548
−0.00229
0.00453
The matrix data shown in the above Table 1 includes, for example, 61 wavelength-range parameters (coefficient sets) p 1 to P 61 in which a wavelength range of 400 nm to 700 nm is divided at 5 nm intervals. The parameters p 1 to p 61 are constituted by coefficients, k pr , k pg and k pb (p corresponds to p 1 to p 61 ) for matrix calculation.
Then, in the color space conversion processing circuit 44 , matrix calculation is carried out according to the following mathematical formula 1 by referring to the above coefficients, k pr , k pg and k pb , and RGB signals output from the first color conversion circuit 43 .
[
λ
1
λ
2
λ
3
]
=
[
k
1
r
k
1
g
k
1
b
k
2
r
k
2
g
k
1
b
k
3
r
k
3
g
k
3
b
]
×
[
R
G
B
]
[
Mathematical
Formula
1
]
More specifically, where the parameters, for example, p 21 (center wavelength 500 nm), p 45 (center wavelength 620 nm) and p 51 (center wavelength 650 nm) shown in Table 1, are selected as λ 1 , λ 2 and λ 3 , (−0.00119, 0.002346 and 0.0016) of p 21 , (0.004022, 0.000068 and −0.00097) of p 45 and (0.005152, −0.00192 and 0.000088) of p 51 may be substituted as coefficients (k pr , k pg and k pb ).
Then, the color-space conversion processing circuit 44 is provided with a mode selector 45 for selecting either a spectral image of one waverange (narrowband) (monochrome mode) or a spectral image of three wavelength ranges (three-color mode) (the mode selector may be provided with a two-color mode for selecting two colors). The mode selector 45 is connected at the rear stage with an amplifier circuit 46 (automatic gain control circuit and the like may be acceptable). The amplifier circuit 46 gives the gain values e 1 , e 2 and e 3 , to λ 1 , λ 2 and λ 3 signals for forming a spectral image, respectively, there by outputting amplified signals of e 1 ×λ 1 , e 2 ×λ 2 and e 3 ×λ 3 . Further, where a monochrome mode is selected, any one of the λ 1 , λ 2 and λ 3 signals is amplified.
The amplifier circuit 46 is provided with a second color conversion circuit 47 for inputting λ 1 , λ 2 and λ 3 signals amplified by gain values of e 1 , e 2 and e 3 , as Rs, Gs and Bs signals, in order to conduct a processing which corresponds to conventional RGB signals and converting Rs, Gs and Bs signals to Y/C signals and a gamma processing circuit 48 for conducting 48 γ correction. Output signals of the gamma processing circuit 48 are supplied to the mirror image processing circuit 29 shown in FIG. 2 .
FIG. 3 shows a movement constitution example of the above-described noise removal circuit 27 . Frame images such as F 1 , F 2 , F 3 . . . are input sequentially to the noise removal circuit 27 . An image F 1 of the memory portion 27 c and an image F 2 of the memory portion 27 b are added at a coefficient ratio of 1/(final comparison number), for example, and sent to a comparison portion 27 d . An image F 3 of the memory portion 27 a is also added to images of F 1 +F 2 at the coefficient ratio and compared at the comparison portion 27 d . Consequently, as shown at the comparison portion 27 d , signals of noise n 1 , n 2 and n 3 for the respective images can be obtained and these signals of noise n 1 , n 2 and n 3 are deducted from an image signal of F 1 , thereby removing noise n 1 of the image F 1 . More specifically, noise components in principle do not exist at the same place on the screen. If a plurality of images (F 1 , F 2 , F 3 . . . ) are added for comparison (or equation), the noise components become small and in removing noise the number of frame images to be processed such as comparison can be increased to elevate the noise removal rate. In the noise removal circuit 27 of the present embodiment, where one (or two) images are compared in forming an ordinary image, two or more (three or more) images are to be compared in forming a spectral image.
Further, in the noise removing processing, when gain values e 1 , e 2 and e 3 are elevated in the amplifier circuit 46 , the noise removal rate is also elevated accordingly. More specifically, depending on elevation (lowering) of the gain values e e , e 2 and e 3 images to be compared are increased from two to three or from three to four (or decreased). Further, another noise removing processing can also be used in addition to the foregoing. The DSP 25 may be arranged on the scope 10 .
The embodiment is constituted as described above. As shown in FIG. 2 , in the scope 10 , the CCD driving circuit 16 drives the CCD 15 , by which imaging signals of an object to be observed are output from the CCD 15 . The signals are subjected to the correlated dual sampling at the CDS/AGC circuit 17 and to the amplification by the automatic gain control, and then supplied via the A/D converter 18 to the DSP 25 of the processor unit 12 as a digital signal. In the DSP 25 , gamma processing is given to output signals from the scope 10 , and also color conversion processing is given to signals obtained via color filters of Mg, Ye, Cy and G, thereby forming Y/C signals made up of a brightness (Y) signal and a color difference (R−Y, B−Y) signal. Output of the DSP 25 is usually supplied, as an ordinary color image signal, to a mirror image processing circuit 29 , a mask generating circuit 30 and a character generating circuit 31 by the selector 26 a (also by the selector 26 b when the noise removal circuit 27 is used). After a predetermined processing at these circuits, the output is supplied via the D/A converter 32 to a monitor, and ordinary color images of an object to be observed are displayed on the monitor.
When an operating switch arranged on an operation portion and others for forming a spectral image are depressed, the selectors 26 a and 26 b changes Y/C signals output from the DSP 25 so as to be supplied to the spectral image-forming circuit 28 via the noise removal circuit 27 . In the noise removal circuit 27 , noise components are removed from the Y/C signals. As described with reference to FIG. 3 , where a two-frame image (obtained according to time sequence) as an image to be compared in forming an ordinary color image, an image made up of three frames or more is compared to conduct processing at a higher noise removal rate.
In this instance, since three wavelength ranges of λ 1 , λ 2 and λ 3 signals are selected by an operator, the microcomputer 35 reads matrix (coefficient) data corresponding to the three selected wavelength ranges from the memory 36 (Table 1) to supply the data to the spectral image-forming circuit 28 . Then, in the spectral image-forming circuit 28 shown in FIG. 1 , a reverse gamma (γ) processing circuit 42 conducts a reverse gamma correction. More specifically, as shown in FIG. 4 , the relationship between the input signal and the output signal can be given as a curve (quadratic curve) 101 in view of the characteristics of a CRT indicator and others. In the DSP 25 , gamma correction which is a curve 102 is provided so that the relationship between the input and the output can be given as linear characteristics 103 . Then, in the reverse gamma processing circuit 42 , the curve 101 is subjected to the reverse gamma correction, by which the signals are restored to an original state before gamma correction. It is, therefore, possible to avoid the distortion of matrix calculation for forming a spectral image in a subsequent stage.
The out put of the reverse gamma processing circuit 42 is supplied to a color-space conversion processing circuit 44 after conversion of Y/C signals to RGB signals by a first color conversion circuit 43 . In the color-space conversion processing circuit 44 , matrix calculation is conducted according to the mathematical formula 1 for forming a spectral image by referring to the RGB signals and matrix data. For example, where p 21 (center wavelength 500 nm), p 45 (center wavelength 620 nm) and p 51 (center wavelength 650 nm) are selected as three wavelength ranges (λ 1 , λ 2 and λ 3 ), signals of λ 1 , λ 2 and λ 3 can be determined from the RGB signals by matrix calculation according to the following mathematical formula 2.
[
λ
1
λ
2
λ
3
]
=
[
-
0.00119
0.002346
0.0016
0.004022
0.000068
-
0.00097
0.005152
-
0.00192
0.000088
]
×
[
R
G
B
]
[
Mathematical
formula
2
]
Where a three-color mode is selected by a mode selector 45 , λ 1 , λ 2 and λ 3 signals are supplied to an amplifier circuit 46 , and where a monochrome mode is selected, any one of the λ 1 , λ 2 and λ 3 signals is supplied thereto. Then, the signals are amplified by the respective gain values of e 1 , e 2 and e 3 to obtain signals of e 1 ×λ 1 , e 2 ×2 and e 3 ×λ 3 . These gains of e 1 , e 2 and e 3 are given the same value in forming a basic spectral image and the λ 1 , λ 2 and λ 3 signals are amplified at the corresponding rate, thereby making it possible to amplify signals without loss of the information included in the selected wavelength components.
The gains of e 1 , e 2 and e 3 may be given a different value depending on the selected wavelength ranges as λ 1 , λ 2 and λ 3 signals. In this case, the noise removal rate is increased in the noise removal circuit 27 , depending on respective increased gains of the λ 1 , λ 2 and λ 3 signals, and images to be compared are increased, for example, from two frames to three or four frames, thereby forming a favorable spectral image in which noise is reduced.
Amplified signals output from the amplifier circuit 46 are supplied to a second color conversion circuit 47 as signals of Rs (=e 1 ·λ 1 ), Gs (=e 2 ·λ 2 ) and Bs (=e 3 ·λ 3 ). Further, where a monochrome mode is selected, any one of the signals of λ 1 , λ 2 and λ 3 (for example, e 2 ·λ 2 when λ 2 is selected) is supplied to the second color conversion circuit 47 as signals of Rs, Gs and Bs. In the second color conversion circuit 47 , λ 1 , λ 2 and λ 3 signals which are amplified as signals of Rs, Gs and Bs are converted to Y/C signals (Y, Rs−Y and Bs−Y) and thereafter supplied to a gamma (γ) processing circuit 48 . As described above, a reverse gamma correction is conducted for forming a spectral image, or gamma correction is conducted so that the input and the output can be linear when the image is displayed on a monitor. Then, the output of the gamma processing circuit 48 is supplied to a mirror image processing circuit 29 shown in FIG. 2 and thereafter processed in a similar way as forming an ordinary image. A spectral image signal is supplied via a D/A converter 32 to a monitor and others.
As described above, a spectral image displayed on a monitor and others is constituted by color components of wavelength ranges shown in FIG. 5 and FIG. 6 . More specifically, FIG. 5 is conceptual diagram in which three wavelength ranges forming a spectral image are superimposed on spectral sensitivity characteristics of color filters on the CCD 15 (the color filter is not in agreement with the sensitivity graduation of wavelength ranges corresponding to λ 1 , λ 2 and λ 3 signals). FIG. 6 is a conceptual diagram in which three wavelength ranges are superimposed on the reflection spectrum of the body. The wavelengths of p 21 , p 45 and p 51 selected as λ 1 , λ 2 and λ 3 signals in the embodiment are color signals having the wave range of approximately ±10 nm, with the center wavelength being 500 nm, 620 nm and 650 nm in sequence, as illustrated in the diagram. Displayed are spectral images (moving image and still image) constituted by combinations of colors of the three wavelength ranges.
Next, a description is given for a case where a gain of the amplifier circuit 46 is set to a different value to extract specifically colored microstructures such as blood vessels and cancerous tissues. More specifically, if a wave range made up of narrow bands is selected, which constitutes a specific color showing blood vessels or cancerous tissues, a spectral image which extracts and high lights the specific color concerned can be obtained. Where a wave range capable of visualizing blood vessels is selected as λ 1 , λ 2 and λ 3 signals and a red wave range is established, for example, a gain of λ 3 (e 3 ) is made 1.2 times greater than a gain of λ 1 (e 1 ) and gain of λ 2 (e 2 ) [e 3 =1.2×(e 1 ,e 2 )], it is possible to form a spectral image in which microstructures of blood vessels are highlighted. In increasing the gains of the λ 1 , λ 2 and λ 3 signals, a specified color is highlighted greatly and noise is also increased accordingly. Therefore, images to be compared in the noise removal circuit 27 are increased from three to four frames, five or six frames, depending on the degree of the increased gain, to reduce the noise.
In the embodiment, the amplifier circuit 46 is arranged inside the spectral image forming circuit 28 . Where all the λ 1 , λ 2 and λ 3 signals are amplified at the same rate, an automatic gain control circuit of the CDS/AGC circuit 17 arranged inside the scope 10 may be used in place of the amplifier circuit 46 . In other words, if the gain of the automatic gain control circuit is increased in forming a spectral image, the spectral image with a favorable brightness can be obtained.
Further, in the embodiment, the noise removal circuit 27 is arranged in the stage prior to the spectral image-forming circuit 28 . The noise removal circuit 27 may be arranged inside the spectral image-forming circuit 28 , for example, at the stage subsequent to the amplifier circuit 46 . In addition, regarding the reverse gamma processing, the DSP 25 shown in FIG. 2 may be changed and controlled so that no gamma processing is conducted in forming a spectral image and the reverse gamma processing circuit 42 is not provided inside the spectral image-forming circuit 28 .
In the endoscope apparatus of the present invention, reduction in brightness due to the constitution with narrow-band wavelength ranges can be solved, thereby making it possible to form and display a spectral image excellent in brightness level. It is also possible to suppress increases in noise components due to amplification and keep spectral images in good quality. Further, specified microstructures such as blood vessels and specifically-colored tissues can be extracted to provide valuable information on an object to be observed, which is helpful in making a diagnosis.
The entire disclosure of each and every foreign patent application from which the benefit of foreign priority has been claimed in the present application is incorporated herein by reference, as if fully set forth.
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An endoscope apparatus comprises: an endoscope comprising an imaging device that forms a color image signal of a body to be observed; a storage portion that stores matrix data for forming a spectral image based on the color image signal; a spectral image-forming circuit that conducts matrix calculation based on the color image signal by using the matrix data of the storage portion and forms at least one spectral image signal each of which corresponds to an arbitrarily selected wavelength range; and an amplifier circuit that amplifies said at least one spectral image signal formed by the spectral image-forming circuit.
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BACKGROUND AND SUMMARY
The present invention relates to a system for selectively applying either heat or cold to a local area, and particularly when it is desired that the temperature of the applicator be held substantially constant. The present invention is useful in many areas, principally in the medical field. One of the advantages of the present system is that, depending upon the applicator pad which is attached to the system, the applicator may be used as a conventional external applicator, or it may be used during surgery to apply to incisions or open wounds, or it may be used to rapidly cool or re-heat an organ during transplant, etc.
The present invention is preferably used with an applicator pad of the type disclosed in co-owned U.S. patent application Ser. No. 381,733, of Francis C. Moore and Leon R. Perkinson, for "Disposable, Sterile Temperature Control Applicator Pad for Medical Application", filed July 23, 1973.
Heat applicators have long been used in the medical field, and they frequently take the form of a padded or blanket type of applicator provided with internal resistive wiring for generating heat. Probably the most commonly used type of cold applicator in the medical field is a flexible plastic package containing two chemicals which, when mixed absorb heat. The chemicals are packaged on either side of a rupturable membrane so that the application of pressure to the exterior of the package ruptures the membrane and causes the fluids to mix and producing the heat-absorbing reaction. Another type of cold applicator uses a compressor, refrigerant, condensing and evaporator coils, and a permanent or non-disposable applicator. Such units are heavy and cumbersome.
The present invention uses a heat transferring liquid stored in a reservoir, such as a standpipe, which is pumped by a peristaltic pump through a heat exchanger containing thermoelectric diodes. As is known, if a current is forced in one direction (anode to cathode) through a thermoelectric diode, the diode will produce heat through ohmic losses. If a voltage of opposite polarity is applied to the junctions of the diode, then the diode will absorb heat from its surrounding area. Control circuitry, under control of an operator, determines which polarity of electrical potential is applied to the thermoelectric diodes in the heat exchanger, and in either case the applied voltage is a rectified sine wave. The control circuitry also determines the firing angle at which the applied voltage is coupled to the thermoelectric diodes, and this firing angle is adjustable. Hence, the operator, in addition to determining whether the system will supply heat to the transfer liquid or absorb heat from the transfer liquid, may adjust the temperature of the transfer liquid in either the hot or cold region. A temperature-sensitive transducer is associated with the passageway from the transfer liquid reservoir and included in the electronic control circuitry in such a way as to regulate the temperature of the transfer liquid once a setting has been made by the operator.
Another feature of the invention is that a second subsystem of reservoir, heat exchanger and pump may be used, connecting the shaft of the second peristaltic pump in tandem with the shaft of the first so that they are driven by a single motor. In this system, the second fluid system may be used, for example, to flush a transplant organ with saline solution at a controlled temperature, either hot or cold or successively cold and hot. Thus, great flexibility in usage is provided. In the case of one heat transferring liquid system, it is preferred that the total liquid in the system, including reservoir, heat exchanger and tubing be less than about two quarts, and the liquid may be water. This permits a very rapid response in the applicator pad to changes in temperature setting. Further, the present system provides greater conduction of heat to or from the application surface because it permits the use of a wet applicator pad. Such pad, as disclosed in the above-identified application further permits the application of medicaments or sterilizing agents to the application area.
Other features and advantages of the present will be apparent to persons skilled in the art from the following detailed description of a preferred embodiment accompanied by the attached drawing.
THE DRAWING
FIG. 1 is a perspective view, partly broken away, of a system constructed according to the present invention;
FIG. 2 is a diagrammatic showing of the elements of the heat transferring liquid loop, showing two pumps in tandem;
FIG. 3 is a circuit schematic diagram of the controller for the present invention; and
FIG. 4 is an idealized waveform of the voltage applied to the thermoelectric diodes, illustrating adjustment of the duty cycle.
DETAILED DESCRIPTION
Referring then to FIG. 1, reference numeral 10 generally designates a console which houses the heat exchanger, pump, control circuitry and so on for the present invention. The console 10 is portable, including an upper handle 11. The front portion of the console 10 includes a faceplate panel 12 on which are mounted the operator controls and signal lights. A window 13 in the faceplate panel 12 permits the operator to view the amount of heat transferring liquid which is present in the reservoir. Preferably, the rerservoir takes the form of a standpipe, designated 14 in FIG. 2, the heat-transferring liquid being denoted 15.
Returning to FIG. 1, a peristaltic pump 16 is mounted to the lower portion of the faceplate panel 12, and the lower portion of that panel is partially broken away to show a drive motor 17 and a fluid manifold 18, to be discussed presently.
On the faceplate panel 12, there are an ON/OFF switch 20, a hot/cold switch 21, a green indicator light 22 for "COLD" a red indicator lamp 23 for "HOT", and a manually adjustable temperature dialing switch 24.
The heat-transferring liquid is communicated from the applicator 18 through a first conduit 30 to an applicator pad generally designated P; and the liquid is returned to the manifold 18 by means of a second conduit 31. As indicated above, the pad P may be constructed according to the teachings of the above-identified patent application Ser. No. 381,733 of Francis C. Moore and Leon R. Perkinson, for "Disposable, Sterile Temperature Control Applicator Pad for Medical Application", filed July 23, 1973. Alternative shapes may be used, depending upon application; and briefly, the pad P includes two sheets of thin plastic material laminated together to form a serpentine conduit through which the heat transferring liquid is communicated, and an outer layer of absorbent material which may be wet in order to improve heat transfer qualities. Further, the pad P may be an applicator which has a special shape, depending upon the application area.
It is considered an important feature of the invention that the applicator pad P is disposable and may take on various forms as this greatly expands the utility of the system. By using a variable volume reservoir, such as a standpipe 14 for the heat-transferring liquid, the amount of liquid in the applicator pad P does not affect system operation. Further, by placement of the temperature-sensitive device as will be disclosed below, regulation of the temperature of the heat-transferring liquid is practically independent of load so that the design and volume of the applicator pad P does not seriously affect system operation.
Turning now to FIG. 2, fluid 15 from the reservoir 14 is coupled through a bored conduit 33 and an exterior conduit 34 to the heat exchanger and control circuitry functionally indicated by the block 36. As mentioned, the height of the heat-transferring liquid 15 in the standpipe 14 may be observed through the window 13 on the faceplate panel of the console 10.
A temperature-sensitive resistor or "thermistor" 37 is located in the conduit 33 at a location adjacent the outlet of the reservoir 14 and, more importantly, sensing the temperature of the heat-transferring liquid prior to forcing the liquid through the heat exchanger or through the applicator pad (which represents the "load"). With this arrangement, control of the temperature of the heat-transferring liquid has been facilitated and made substantially independent of variations in load (within design range) such as may be caused by differences in contact area, differences in applicator pad heat-transfer characteristics or volume, and so on. The resistance of thermistor 37 is an inverse function of temperature. The control circuitry will be explained in more detail below.
After exiting from the heat exchanger, the heat transferring liquid flows back through the manifold 18 and a flexible tube 40 which forms a part of the peristaltic pump 16. Pumps of this type are well known in the medical field, comprising a plurality of freely rotatable orbital rollers 45 mounted between end plates, one of which is shown at 46. The end plates are driven in rotation by a shaft 47. A continuous fluid-tight tube, such as that shown at 40, is arranged in a race through the pump which is spaced from the outer ends of the rollers 45 a distance sufficient only to permit collapse of the tube 40, so that the shaft 47 turns, the orbital rollers 45 are moved to first close the flexible tube 40, then force a quantum of liquid trapped in it along the direction of movement of the orbital rollers to an outlet which, in this case, is coupled back to the manifold 18 at 48. The heat-transferring liquid is thence communicated through an internal bore 49 to the flexible conduit 30 and the applicator pad P. The liquid returning from the pad P through the conduit 31 is coupled to the standpipe 14 by means of a bore 50 which, again, is in the manifold 18. A conduit 52 communicates the fluid in the discharge bore 50 with a pressure relief valve 53 in the manifold 18. The input to the pressure relief valve 53 is coupled to the conduit 49 which feeds the applicator pad P. Thus, should the pad P or the flexible tubes 30, 31 become occluded, the resulting increase in pressure appearing in the conduit 49 will actuate the pressure relief valve 53, and the fluid will be transmitted directly to the reservoir or standpipe 14. This will prevent bursting of any portions of the system near the subject on whom the pad P is applied until the obstruction is removed or obviated.
As has already been mentioned, if it is desired to adapt the invention to include a second heating or cooling system which is controlled independently of the first, a second paristaltic pump 16A may be added, with its shaft 47A connected in tandem with the previously-mentioned shaft 47 of the pump 16, so that they are driven by a common motor. As best seen in FIG. 1, the housing for the pump 16 includes a number of bosses 56 which facilitate mounting of the second pump to the front of the console 10, and the shaft 47 may be slotted as at 57 to facilitate driving of the second shaft.
Referring again to FIG. 2, associated with the second pump 16A is a second manifold 18A as well as a second heat exchanger and control circuitry, reservoir, and so on, which are not shown because they may be similar to those corresponding elements which have already been disclosed. Thus, the second fluid system may contain a separate fluid and a separate control. This would be useful, for example, in a transplant operation wherein one applicator pad may be used to reduce edema on the incision or to surround the organ being transplanted, while the second fluid system could be used to flush the organ with a saline solution to preserve it.
Among the advantages of using a peristaltic pump are that electrical isolation between the applicator and the control system are greatly reduced, thereby reducing the shock hazard. Further, the fluid is completely isolated from the pumping mechanism and can therefore be maintained is a sterile condition if this is desired.
ELECTRICAL CONTROL SYSTEM
Turning now to FIG. 3, reference numeral 70 designates the input lines from a conventional 120-volt, 60 Hz. source, such as wall outlet. One of the electrical feed lines is provided with a fuse 71 and the contacts 20A of the ON/OFF switch are also connected in this line. Preferably, the ungrounded or "HOT" line is fused and provided with the ON/OFF switch. Power is fed once the contacts 20A are closed to a fan motor 73 for circulating room air around the heat exchanger and to the winding of the motor 17 which drives the pump 16.
Power is also supplied to the HOT/COLD switch 21 which is a four-pole, double-throw switch having a "HOT" and a "COLD" position. One of the legs or decks of the switch 21, designated 21A in FIG. 3 is used to couple power to the filaments of the lamps 22, 23. In the position shown (namely, the "HOT" position), the red lamp 23 is illuminated, and power is also coupled to the coil of a relay R 1 . The other four decks of the switch 21 are designated respectively 21B, 21C and 21D, and will be discussed below.
The contacts of the relay R 1 form a double-pole, double-throw switch generally designated 75 in the left half portion of FIG. 3. When the coil of the relay R 1 is energized, the contacts 75 are in the position shown for coupling energy through an inductor L to the thermoelectric diode bank generally designated by reference numeral 76.
Power is coupled to the contacts 75 from a bridge circuit B1 which, in turn, is energized by means of a transformer T1. An indicator lamp 78 is connected across the terminals of the secondary of the transformer T1, and this lamp is located on the faceplate panel to indicate to the operator that current is being fed to the thermoelectric diode bank 76, when it is lit. A series of three thermostats designated respectively 80, 81 and 82 are located between the main power switch 20A and the primary of the transformer T1. Each of the thermostats 80-82 is a normally-closed thermostatic switch such that if the ambient temperature exceeds a predetermined value, the switch opens. The thermostat 80 is located in the main power supply and will open if the temperature rises above 190° F. The thermostats 81 and 82 are both located in the heat exchanger, one opening at 130° F. and the other opening at 190° F., thereby providing a redundant protection against overheating in the heat exchanger.
The primary winding of the transformer T1, as mentioned, has one terminal connected to the "HOT" power line through the thermostats. The other terminal is coupled to the other power line through a controlled semi-conductor switch which, in the illustrated embodiment is a triac Q1. A resistor 83A and a capacitor 83B form a noise suppressing network connected between the second terminal of the primary winding of transformer T1 and ground or common. Thus, the polarity of voltage fed to the diode bank 76 is controlled by the contacts 75 of relay R1 which, in turn, is controlled by the manual selection switch 21A. However, the duty cycle or duration of coupling of power to the contact 75 from the bridge B1 is determined by control of the triac Q1, as will presently be discussed. Turning now to the upper left-hand portion of FIG. 3, a limiting resistor 84 couples power to a second bridge circuit B2. The output of the bridge B2 is coupled through a limiting resistor 87 to a Zener diode 88 which establishes a fixed DC potential for the subsequent circuitry, which potential is established on a line designated 89. The deck 21B of the switch 21 has a terminal 90 connected to the wiper blade and first and second fixed terminals 91, 92. Similarly, the deck 21C has a terminal 93 connected to the wiper arm and first and second fixed terminals 94 and 95. The deck 21D also has a terminal 96 connected to the wiper arm and first and second fixed terminals 97 and 98. The contact 91 of deck 21B is connected to the contact 95 of deck 21C. Similarly, contact 92 of deck 21B is connected to contact 94 of deck 21C. Terminals 93 and 96 respectively of decks 21C and 21D are also connected together.
It will be observed from the above that the decks 21B and 21C are connected to form a double-pole, double-throw switch. The thermistor 37, shown schematically in FIG. 3 as a resistive element is connected between the terminal 95 and the anode of a diode 100. The cathode of the diode 100 is connected to the gate lead 101 of a unijunction transistor 102. A capacitor 103 is connected between the gate lead 101 and the negative terminal of bridge B2. A fixed resistor 105 and a variable resistor 106 are connected in series between a positive terminal of the bridge B2 and the gate lead 101 of the unijunction 102. The junction between the thermistor 37 and diode 100 is coupled by means of a fixed resistor 109 to the contact 92 of the deck 21B.
The fixed contact 98 of the deck 21D is connected to the movable contact of a multi-position switch generally designated by reference numeral 110 and having five fixed contacts, as illustrated. Resistors 111-115 are connected respectively between these fixed contacts and the negative terminal of the bridge B2. Similarly, the fixed contact 97 of deck 21D is connected to the movable contact of a second multi-position switch generally designated 116. Fixed resistors 117-21 are connected respectively between these fixed contacts and the negative terminal of the bridge circuit B2.
The switches 110, 116 may be a decade switch having two separate decks, each deck being provided with ten individual contacts. However, only five contacts are used for each deck in a manner such that only one deck is connected to a resistor at a given time. That is, the switch 116 may have the first five positions connected to the resistors 117-21 whereas the switch 110 may have the second five positions connected to the resistors 111-115. The switches 110, 116 comprise the manually temperature control switch 24 of FIG. 1. The switch 116 controls the temperature when the system is operating in the "COLD" mode, and the switch 110 controls the temperature setting when the system is operating in the "HOT" mode.
It will be observed that the junction between the fixed resistor 109 and the thermistor 37 comprises a voltage take-off point for the triggering of the unijunction transistor 102 which is connected to operate as a monostable circuit, as will be discussed. When the switch 21 is in the position shown (i.e. the HOT mode), the thermistor 37 is on the lower voltage side of this take-off junction relative to the gate lead 101 so that as the temperature of the heat-transferring liquid increases, the resistance of the thermistor 37 will decrease correspondingly, and thereby reduce the take-off voltage from the voltage divider network comprising the resistor 109, thermistor 37, and one of the fixed resistors 111-115. This will retard the firing angle of triac Q1 and supply less current to the bank of thermoelectric diodes 76 until a state of equilibrium is reached.
When the switch 21 is switched to the COLD state (that is, the movable contacts are connected to the contacts 91, 94 and 97), the thermistor 37 is above the voltage take-off point of the voltage divider network. In this state, the voltage divider network includes the thermistor 37, the resistor 109, and one of the fixed resistors 117-121.
In summary, the voltage at the anode of diode 100 is a control signal representative of the difference between the actual temperature of the heat-transferring liquid (sensed by thermistor 37) and a desired temperature (as determined by the setting of the temperature control switches 110 or 116 depending upon the mode of operation).
A resistor 130 is connected between one power terminal of the unijunction transistor 102 and the lead 89, and a second resistor 131 is connected in the other terminal circuit of the unijunction transistor 102. The unijunction transistor 102 and its associated circuitry, particularly capacitor 103, resistors 105, 106 and the voltage divider circuitry feeding current to diode 100 is arranged so that the unijunction transistor 102 generates an output pulse for each cycle of the 60 Hz. input voltage. This output or trigger pulse is synchronous with the voltage being applied through transformer T1, bridge B1 and switch 75 to the bank of thermoelectric diodes 76. The triggering time within a given cycle will be advanced or retarded by the previously mentioned control signal depending upon the mode in which the switch 21 is set (hot or cold), the temperature of the liquid taken from the standpipe, and the particular setting of whichever of the temperature control switches 110, 116 is connected in circuit.
OPERATION
To summarize the operation of the control circuitry, assuming that the switch 21 is set in the "HOT" mode, as illustrated, a voltage divider network will be set up comprising resistor 109 in series with the thermistor 37 and one of the resistors 111-115, depending upon the setting of switch 110. The resistors 111-115 are calibrated such that a higher resistance value produces a higher operating temperature for the heat transferring liquid since it will advance the firing angle for the triac Q1.
The resistance of the thermistor 37 is an inverse function of temperature--that is, as temperature rises the ohmic resistance of the thermistor 37 decreases. Hence, for the "HOT" setting mentioned, as the temperature of the liquid flowing from the standpipe reservoir increases, the value of resistance of the thermistor 37 will decrease, thereby withdrawing some of the current that would otherwise be used to charge the capacitor 103 at the beginning of a cycle. Thus, the magnitude of the control signal will be reduced. This will retard the firing angle of the unijunction transistor 102. In other words, the charge on the capacitor 103 must build to a fixed point in order to trigger the unijunction transistor 102. The lower the value of resistance in the lower leg of the voltage divider network feeding the diode 100, the lesser current will be available to charge the capacitor 103, and this will retard the firing angle. Still referring to operation in the "HOT" mode, as the temperature of the liquid reduces, the value of resistance of the thermistor 37 will increase, and this will advance the firing angle for the unijunction transistor 102, as is desired because as the temperature of the heat-transferring liquid reduces while operating in the "HOT" mode, more electrical energy must be converted to heat energy by the thermoelectric diode bank 76 to reach an equilibrium.
When operating in the "COLD" mode, the position of the movable contacts of the switch 21 are reversed from those illustrated, thereby reversing the relative positions of the thermistor 37 and fixed resistor 110 in the voltage divider network feeding the diode 100. Again, the temperature is determined by the setting of the switch 116, and as the temperature of the liquid rises, the resistance value of the thermistor 37 will decrease. However because the resistor is now in the top leg of the voltage divider network, more current will be available to charge the capacitor 103, and this will advance the firing angle, as is desired when operating in the "COLD" mode and the temperature of the heat-transferring liquid rises. Conversely, when the temperature of the liquid reduces, the resistance value of thermistor 37 will increase, thereby reducing the current available to charge the capacitor 103 per cycle and retarding the firing angle, again achieving the desired result when operating in the "COLD" mode and the temperature of the liquid reduces.
Thus, the output signal of the unijunction transistor 102 is a voltage level or pulse which reduced to zero at the end of each cusp of the full-wave rectified input voltage. The firing angle is advanced or retarded as just discussed, and this signal is coupled to the gate lead of a Silicon Controlled Rectifier (SCR) 135. The output pulse of the SCR 135 is coupled through a diode 136 and a voltage divider network including resistors 140 and 141 to the gate lead G of the triac Q1, causing it to conduct, and thereby completing the circuit for the primary winding of transformer T1. When the circuit is completed, the sinusoidal input wave will energize bridge circuit B1 (and hence, the bank 76 of thermoelectric diodes) in the polarity selected by relay R1. Briefly, a triac is an AC switch such that when the input or control current reaches a certain value, the triac conducts causing a short circuit between the terminals MT1 and MT2. The triac is turned off when the polarity of the power reverses and the current fed to the gate lead falls below a predetermined value, such as five microamps.
In summarizing the operation of the control system, reference is made to FIG. 4 wherein two half-cycles of a full-wave rectified source voltage are shown. The polarity of this voltage as applied to the bank 76 of thermoelectric diodes is determined by the position of the contacts 75, which, in turn, is determined by the position of the deck 21A of the switch 21. Assuming that the system is operating in the "HOT" mode, and that the firing angle is the time T1 as indicated in the cycle, the shaded area indicates the amount of time during each cycle in which power is supplied to the bank 76 of thermoelectric diodes to generate heat. If the heat-transferring fluid becomes hotter, the resistance value of the thermistor 37 will decrease, and this will retard the firing angle to reduce the shaded area of FIG. 4 and to apply less average power to the diode bank 76. If, on the other hand, the temperature of the fluid reduces, the firing angle will be advanced and thereby provided more average power to the diode bank. When operating in the "COLD" mode, the operation of the circuitry is reversed because in this mode, as the temperature of the liquid rises, it is desired to increase the average power to the diode bank 76 (but in reverse polarity, of course) so as to withdraw more heat from the liquid.
The thermoelectric diode bank may have as many diodes connected in series branches with the branches connected in parallel, as are required for the amount of heating or cooling for which the system is designed. Thermoelectric diodes of this type are well known in the art, operating according to the Seebeck/Peltier effect, and they are commercially available.
To summarize the principal advantages of the invention, it avoids the use of a bulky, heavy compressor in providing cooling capability for medical applications. Not only is it lightweight and therefore portable, but the same source (namely, the thermoelectric diodes) is used both for heating and cooling the heat-transferring liquid which is transmitted to the applicator pad.
By using a minimal amount of heat-transferring liquid, (approximately two quarts or less in the total system), and by employing an applicator pad having a thin wall between the heat transfer liquid and the applicator surface, very rapid response times can be achieved for reducing the temperature of the surface to which the applicator pad is applied. This is particularly useful in skin grafts or the like, where it is also useful to achieve a very rapid and substantial temperature change, such as going from extreme "HOT" to very "COLD" or vice versa. By placing the temperature-sensitive thermistor adjacent the outlet of the liquid reservoir and by controlling the temperature of the liquid after it is removed from the reservoir, very close tolerances can be held on the temperature of the liquid, and response time is further reduced. This also facilitates producing large temperature changes with a minimum of heat-pumping capacity.
The use of a peristaltic pump provides excellent electrical isolation between the fluid loop and the applicator surface, and the use of the pressure relief valve in the manifold minimizes accidental spilling of liquid should the flexible applicator pad or tubing leading thereto become occluded.
By using a second peristaltic pump and independent fluid system, one of the fluid loops can be sterile, for use in flushing an organ with saline, and the temperature of the second loop may be independently variable.
The heat exchanger may take the form of a rectilinear copper fluid exchanger having a 1/2 inch conduit milled for conducting the fluid. A first set of four thermoelectric diodes are silver-soldered to the outer surface of one side of the exchanger, and these are connected in series electrically. A second set of four thermoelectric diodes are silver-soldered to the outer surface of the opposite side of the exchanger, and these are also connected in series electrically. The first set of diodes is connected in parallel with the second set.
Having thus described in detail a preferred embodiment of the present invention, persons skilled in the art will be able to modify certain of the structure which has been disclosed and to substitute equivalent elements for those illustrated while continuing to practice the principle of the invention; and it is, therefore, intended that all such modifications and substitutions be covered as they are embraced within the spirit and scope of the appended claims.
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Heat transferring liquid is pumped by a peristaltic pump from a reservoir through a heat exchanger to a disposable applicator pad through flexible conduits. The heat exchanger is provided with thermoelectric diodes which, under control of electronic circuitry, may absorb heat from or transfer heat to the liquid. Further, the control circuitry permits adjustment of the temperature of the applicator pad, whether hot or cold.
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BACKGROUND OF THE INVENTION
This invention relates to a valve actuation device for multi-valve type engines and more particularly to an improved valve actuating device for such engines that provides a compact cylinder head configuration.
It has been known that the performance of an internal combustion engine can be significantly improved by using multiple valves for each cylinder of the engine. The use of multiple valves permits a greater power output for the engine because multiple valves can provide the same effective flow area with lower inertias. For this reason, four valve per cylinder engines are quite common. The performance of an engine can be improved even further by utilizing more than two valves for either the intake and/or exhaust functions. However, as the number of valves increase, there is a difficulty in providing both a compact combustion chamber and one which has a relatively small surface area. Compact combustion chambers are desirable in order to maintain high compression ratios and small surface areas are required so as to prevent undue quenching. In addition, it is the normal practice to employ separate camshafts for driving the intake and exhaust valves. Where multiple camshafts and multiple valves are employed, the overall height and width of the engine can become quite large with conventional constructions.
There is shown in U.S. Letters Patents 4,624,222, issued Nov. 25, 1986, entitled "Intake Valve Structure For Internal Combustion Engine," issued in the name of Masaaki Yoshikawa, and assigned to the assignee of this application, an arrangement wherein a desired combustion chamber configuration can be enjoyed with multiple valves. In conjunction with the arrangement shown in that patent, there are provided three intake valves, two of which reciprocate about axes that lie in a common plane and the third of which reciprocates about an axis that is inclined to this plane. However, the axes intersect along a common line, which line coincides with the rotational axis of the actuating camshaft. Although this arrangement has numerous advantages, the camshaft tends to be relatively highly placed in the cylinder head and this can result in a higher engine height than is desirable. By canting the valves at a greater angle, the camshaft can be lowered but then the width of the engine will increase and the shape of the combustion chamber will not be as advantageous.
It is, therefore, a principal object of this invention to provide an improved arrangement for operating multiple valves of an internal combustion engine.
It is a further object of this invention to provide a valve actuating mechanism employing a camshaft wherein the camshaft is placed relatively low in the cylinder head so as to provide a low engine height and wherein the width of the cylinder head is not increased.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a valve actuating arrangement for an overhead valve internal combustion engine having a pair of valves that reciprocate along axes that lie in planes which intersect along a line. A camshaft is rotatably journaled relative to the cylinder head and cooperates with the valves for actuating them. In accordance with the invention, the rotational axis of the camshaft is disposed closer to the heads of the valves than the line of intersection of the planes of reciprocation of the valves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view taken through the cylinder head and combustion chamber of a single cylinder of a multiple cylinder internal combustion engine constructed in accordance with an embodiment of the invention.
FIG. 2 is a plan view showing the relationship between the valves, valve actuators and camshaft rotational axis.
FIG. 3 is a plan view, in part similar to FIG. 2, showing another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings, an internal combustion engine constructed in accordance with an embodiment of the invention is identified generally by the reference numeral 11. Only a portion of the engine 11 has been depicted and specifically only that portion of the engine dealing with the cylinder head and combustion chamber. In all other regards, the engine 11 may be considered to be conventional and, for that reason, it is not believed to be necessary to illustrate the remaining components of the engine. In addition, the illustration of only a single cylinder is believed to be all that is required for those skilled in the art to understand the invention.
The engine 11 is comprised of a cylinder block 12 in which one or more cylinder bores 13 are formed. Pistons 14 reciprocate in the cylinder bores 13 and are connected by means of connecting rods toa crankshaft (not shown) for driving the crankshaft in a known manner.
A cylinder head, indicated by the reference numeral 15, is affixed to the cylinder block 12 in a known manner. The cylinder head 15 has individual recesses 16 that cooperate with the cylinder bores 13 and pistons 14 to describe variable volume chambers, sometimes hereinafter referred to as "combustion chambers".
The engine 11 is provided with an induction system that is comprised of three intake valves, indicated generally by the reference numerals 17, which control the flow of an intake charge delivered from intake passages 18 through intake valve seats 19 into the combustion chamber 16. The charge is supplied to the intake passages 18 in any suitable manner which may include an intake manifold and fuel injection system. The intake passages 18 may be siamesed or there may be an individual intake passage 18 for each valve seat 19. The heads and stems 21 of the valves 17 are disposed in a relationship as set forth in aforenoted U.S. Letters Patent 4,624,222 so as to provide a compact combustion chamber.
The valves 17 have individual valve stems 21 that are slidably supported in valve guides 22 pressed into the cylinder head 15. As noted in aforenoted U.S. Pat. No. 4,624,222, two of the valve stems 21a are disposed at a greater angle to the axis of the cylinder bore 13 than the remaining valve stem 21b. The valve stems 21a lie in a common plane and this plane is intersected by a plane containing the valve stem axis 21b along a line 23.
Thimble type tappets 24 are slidably supported in bores 25 of the cylinder head 13 and cooperate with the tips of the valve stems 21 for opening the valves 17 in a known manner. Coil compression springs 26 encircle the valve stems 21 and urge the valves 17 toward their closed positions.
In accordance with the invention, the intake valves 17 are all operated by means of a single intake camshaft 27 that is rotatably journaled in the cylinder head 15 about a rotational axis 28 which lies closer to the valveseats 19 than the line of intersection 23 of the aforedescribed planes containing the axes of reciprocation of the valve stems 21. As a result, the overall cylinder head height can be reduced from that which would be present if the rotational axis 28 intersected the line of intersection 23 and, as will be apparent, the width of the cylinder head can also be reduced because the camshaft rotational axis is offset inwardly toward the cylinder bore axis by the distance X.
As a result of this configuration, it will be noted that if the thimble tappets 24 are coaxial with the valve stems 21, the point of engagement of the lobes of the camshaft 27 with the heads of the thimble tappets 24 will be offset by the distance X as clearly shown in FIG. 2. This does not present any significant problem since the thimble tappets 24 may be made large enough so as to avoid any significant cocking forces. Alternativley, as shown in FIG. 3, it is possible to keep the point of contact of the cam lobes with the thimble tappets at the center of the thimble tappets if the thimble tappets 24 are offset by the distance X from the center of the valve stems 21a and 21b. Again, this amount of offsetting is so slight that it will not prevent any difficulties in connection with the operation.
The combustion chamgber is completed by means of a pair of exhaust valves 29 that control the flow through exhaust ports 31. The exhaust valves 29, which may reciprocate about axes that lie in a common plane, are operated by means of an exhaust valve camshaft 32 that cooperates with thimble tappets 33 that are slightly supported in bores 34 of the cylinder head 15. Exhaust valve springs 35 urge the exhaust valves 29 to their closed positions.
It should be readily apparent from the foregoing description that the described valve actuating arrangement permits a very simple and compact valve assembly with the desired combustion chamber configuration without increasing the height or width of the engine and specifically of the cylinder head. Although two embodiments of the invention are illustrated and described, various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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Two embodiments of valve driving arrangements for internal combustion engines that permit a low camshaft positioning without adding to the width of the engine. In each embodiment, three intake valves are slidably supported, two in a common plane and the third in a plane that intersects the first plane along a line that is disposed farther from the valve heads than the rotational axis of the camshaft which operates the valves.
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This invention is a continuation in-part of the applicant's patent application bearing Ser. No. 08/336,399 filed on Nov. 9, 1994, U.S. Pat. No. 5,607,556, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
This referenced application discloses a method for continuously producing coke by providing an elongated coking chamber having an annulus, and by force feeding coal in a charging end of the annulus and compacting the coal against the outer and inner walls which form the annulus, and by continuously carbonizing the coal into coke by heating the coal bi-directionally in the annulus of the coking chamber by means of conductive heat as the coal passes through the elongated chamber.
OBJECTIVES OF THE INVENTION
The present invention provides an apparatus to carry out the above referenced method and also a coking chamber that provides a structure that efficiently transfers thermal energy from flues to the coal by conduction. This structure incorporates a highly conductive ceramic material such as silicon-carbide which can withstand high temperature (above 1000° C.) while still maintain its strength, be resistant to chemical attack by gas from coal, and be resistant to the erosive properties of coke. Such material is used in the structural configuration of the coking chamber in which the coal is converted to coke.
Conventionally coke is made in ovens using silica brick which can withstand high temperature, be resistant to chemical attack and be resistant to the erosive properties of coke; however, its conductivity is poor by virtue of its coefficient of thermal conductivity being around 1.7W(mK) when compared to a silicon-nitride bonded silicon-carbide which has a coefficient of thermal conductivity of about 16W (mK)--namely 940% more conductive. Such conductivity makes it possible to drive the thermal energy into the coal at a substantially faster rate than conventionally, thereby increasing the productivity of coke from the coking chamber.
Therefore, the main object of the present invention is to provide an efficient apparatus for the carbonization of materials such as coal within a coking chamber having an annulus formed by an outer wall and an inner wall with a space in between wherein the coal is heated bi-directionally within said space by conduction.
Another object of the present invention is to provide an apparatus for the carbonization of materials such as coal having a coking chamber that possesses structural features that transfer the thermal energy to the coal to be coked in a substantially more efficient manner than conventional coking.
Further another object of the present invention is to provide an apparatus that can carbonize materials at pressure and without causing emissions which are detrimental to the environment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of the apparatus to carbonize materials with the gas treating portion shown in FIG. 1(a) and FIG. 1(b).
FIG. 2 is a partial view of the coking chamber in which the materials are carbonized.
FIG. 3 is an arrangement of tiles containing heating flues.
FIG. 4 is a three dimensional view of tiles with the mating surfaces of the tiles being shown in FIG. 4(a) and FIG. 4(b).
FIG. 5 is a section taken at 5--5 of FIG. 1 showing the structure of the coking chamber.
FIG. 6 is a section of a coking chamber lined with tiles of slightly different configuration than that shown in FIG. 5.
DESCRIPTION OF THE INVENTION
Before proceeding with the description, by way of example "coal" shall be used for the material to be coked; this shall not mean that other materials cannot be used. Reference is made to FIG. 1 wherein the coking chamber is denoted by numeral 10. Numeral 11 is the coal charging equipment and numeral 12 is the coke discharge end. Charging equipment 11 communicates with lockhopper 13 which feeds the coal using valves 14 and 15 for control without causing emissions and loss of system pressure. Coking chamber 10 possesses burners 16 and 17 for providing hot flue gas for indirectly heating the coal. The flue gas is discharged via pipe 18. The raw gas leaves coking chamber 10 via conduit 19 and is collected by main 20 which serves to collect the raw gas from several coking chambers (not shown) similar to chamber 10. A cracker denoted by numeral 22, serves to crack and desulfurize the raw gas from chamber 10. The raw gas from main 20 is guided to enter into gas cracker 22 (in FIG. 1(a)) via pipe 21 (shown broken). Cracker 22 has a top nozzle denoted by numeral 23 for the entry of the catalyst and a bottom nozzle denoted by numeral 24 for the discharge of the catalyst. The cracked, desulfurized gas leaves cracker 22, via port 25. The flue gas from pipe 18 (in FIG. 1), if required to be treated, is directed by means of pipe 26 in FIG. 1(b) which is the continuation of pipe 18, into a contactor which is denoted by numeral 27 (in FIG. 1(b)). Contactor 27 possesses entry point 28 and exit point 29 for the respective receipt and discharge of a catalyst. The treated flue gas leaves contactor 27 via port 30.
The incandescent coke is discharged into a quenching chamber, denoted by numeral 31 via discharge end 12 and via valve 32 (in the open position). Valve 33 in the closed position forms the bottom of quenching chamber 31. Steam and water sprays are provided to chamber 31, which are denoted by numeral 34, in order to cool the coke prior to discharging it onto conveyor 35 via chute 36.
Referring to FIG. 2 for the detailed description of coking chamber 10, the annulus which contains the coal is denoted by numeral 37. This annulus is configured by two concentric walls of tiles, outer wall 38 and inner wall 39. The tiles which make up walls 38 and 39 and which are denoted by numeral 40, are made of a silicon-carbide such as silicon-nitride bonded silicon-carbide with heating flues denoted by numeral 41, being disposed within tiles 40 for the flow of hot flue gases. Flues 41 are preferably disposed axially in tiles 40 in the form of assemblies of groups. Tiles 40 possess a tongue and groove arrangement denoted by numerals 42 and 43 respectively in order to interlock tiles 40 radially. Also tiles 40 possess a tenon and mortise arrangement denoted by numerals 44 and 45 respectively in order to interlock tiles 40 axially. Wall 38 and/or wall 39 may possess a taper to diverge toward discharge end 12 in order to provide relief to the coal passing through annulus 37.
Wall 38 is backed-up by insulation 46 which in turn is contained by outer pressure shell 47, and wall 39 is backed-up by insulation 48 which in turn is contained by inner pressure shell 49. Tiles 40 are also secured to insulation 46 and insulation 48 by means of anchors such as anchor 50. FIGS. 3 and 4 show additional representations of tiles 40 and their interlocking arrangements. FIGS. 4(a) and 4(b) further illustrate the interlocking arrangements of tiles 40. These tiles are laid in courses to form the structure of coking chamber 10.
Referring to FIG. 5 which shows coking chamber 10 in section, the numerals indicate the parts described in FIG. 2. In FIG. 6, the annulus has been omitted in order to show a variation of chamber 10 wherein a single circular wall of tile is employed within which the coal is coked. The outer shell is denoted by numeral 47, the insulation by numeral 46, the heating wall which is made of tile by numeral 38, and the carbonization chamber proper by numeral 51.
The operation of the instant invention will be described using coal by way of example. The coal is fed through lockhopper 13 using valves 14 and 15 in order to prevent gases from escaping from coking chamber 10. The coal is compacted and advanced within chamber 10 by means of charging equipment 11 which includes pushing cylinder(s) 55. The coal is efficiently heated by conduction in annulus 37, by virtue of the high conductivity of tiles 40, and carbonized bi-directionally into coke in the absence of oxygen by the continuous passage of hot gases axially through flues 41 which are disposed in tiles 40. The coal charging rate, and its residence time within chamber 10 are coordinated in such a way as to have the coal converted to coke when the charge reaches discharge end 12. During coking the process pressure in chamber 10 and the pressure in flues 41 are adjusted to minimize migration of gas from chamber 10 into flues 41 through the joints of tiles 40, and vice versa. It is preferred to operate the process pressure somewhat higher than the pressure in the flues in order to force the deposit of carbon in the joints caused by the cracking of hydrocarbons contained in the gases devolatilized from the coal. The flue gas leaving flues 41 is treated in contactor 27 prior to its discharge into the atmosphere to insure that no polluting emissions occur in the event of any raw gas migration from the annulus to the flues. The raw gas released from the coal containing deleterious components such as tar, hydrogen sulfide, ammonia, phenols, cyanide, benzene, etc. is treated in cracker 22.
Hot glowing coke is pushed into quenching chamber 31 while valve 32 is open and valve 33 is closed. Initially steam is injected into chamber 31 to form water gas, this water gas is mixed with the raw gas and both are cleaned in cracker 22. When the water gas reaction slows down and the coke is partially cooled, valve 32 is closed, the injection of steam is stopped, chamber 31 is depressurized, and water is injected to complete the cooling of the coke. The cold coke is discharged into the atmosphere by opening valve 33, without causing pollution. If desired the cooling of the coke can take the form of dry quenching (known in the art) in order to recover the heat from the hot coke.
During carbonization the temperature of tiles 40 is maintained high enough to cause hydrocarbons that come in contact with tiles 40 to cause the cracking of such hydrocarbons against the tiles with the result of deposition of carbon on tiles 40. The operation of carbonization is conducted at pressure which could range from a few ounces to scores of atmospheres, depending upon the ultimate use of the gas produced from the coal. With the aid of process pressure within coking chamber 10, the carbon which is deposited onto tiles 40 is forced to impregnate the tiles and the joints between the tiles to cause the sealing of the tiles themselves as well as the joints.
It is contemplated to assemble several coking chambers, such as chamber 10, together in order to form a battery of producing units to respond to commercial production needs. The details of construction described above are for the purpose of description and not limitation since other configurations are possible without departing from the spirit of the invention. Further other materials besides coal can be carbonized in the apparatus herein described.
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An apparatus for the carbonization of materials, such as coal, comprising an elongated coking retort defined by an annulus which constitutes the coking chamber within which the coal is carbonized indirectly by conduction. In order to provide an efficient mechanism for transferring thermal energy to the coal by conduction, highly conductive tiles equipped with flues and adapted to transport hot flue gas makes up the walls of the annulus within which the coal is carbonized. The raw gas (discharged from carbonization) and the cooled flue gas (discharged from the flues) are collected and separately treated to prevent polluting emissions.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of Provisional Application No. 60/239,753, which was filed on Oct. 12, 2000, and the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The invention disclosed herein is directed to a hydroentangled nonwoven fabric and the making thereof, whereby the outer surface fibers of a single fibrous batt are highly hydroentangled and the inner fibers of the single fibrous batt are lightly entangled, the resulting fabric thus exhibits a low linting, lofty structure, and favorable tactile and ductile softness while obtaining sufficient physical strength.
BACKGROUND OF THE INVENTION
The use of natural fiber materials in medical and industrial applications has been found to be highly advantageous in situations where a non-linting, absorbent pad or wiper is required. A material that has been employed in such applications is found in the Webril material from the Kendall Company of Massachusetts. The Webril material is a compressed, mercerized cotton fibrous batt. The mercerization process involves the swelling of the natural cotton's ribbon like profile into an approximately round profile of larger diameter. Typically, caustic washes are utilized while the cotton batt is under tension to induce the swelling of the cotton fiber. Because of the use of a caustic solution, it is necessary to subsequently treat the cotton material with an acidic solution so as to neutralize the material and render it useable. A number of complicated steps are required to successfully perform the process, with a significant amount of environmentally harmful effluent being produced.
In the interest of forming natural fiber nonwoven pads or wipers without the by-products of mercerization, the application of a resin binder in conjunction with hydroentanglement was explored as evidenced by U.S. Pat. Nos. 2,862,251, 3,033,721, 3,769,659, and 3,931,436 to Kalwaites et al., and U.S. Pat. Nos. 3,081,515 and 3,025,585 to Griswold et al, the disclosures of which are herein incorporated by reference. The application of resin binder was found to have a deleterious effect on the softness of the corresponding nonwoven fabric.
The findings by Evans, U.S. Pat. No.3,485,706, the disclosure of which is herein incorporated by reference, suggested that the impedance of energetic water streams on a fibrous batt could produce a nonwoven fabric by the entanglement of those fibers with one another through the depth of the fibrous batt, thus obviating the need for a resin binder. However, the action of the water streams upon the fibrous batt and the action of entangling the fibers result in a fabric having significantly decreased bulk, and correspondingly decreased tactile and ductile softness.
Various attempts have been made in order to obtain a durable natural fiber nonwoven fabric while maintaining sufficient strength and softness. In U.S. Pat. No. 5,849,647 to Neveu, herein incorporated by reference, a hydrophilic cotton stratified structure is formed by interceding an air-randomized core in between two previously formed, highly fiber oriented carded layers. The stratified layers are subsequently treated with a soda liquor which is then boiled off to render an integrated structure. While a cotton structure performed by the manner described can render an ultimate material that is low linting, the material must undergo substantial processing in the forming of separate and distinct layers and the juxtaposition of those layers during the caustic integration step. U.S. Pat. No. 4,647,490 to Bailey et al., the disclosure of which is herein incorporated by reference, formed an apertured, cotton fiber nonwoven material by hydroentanglement induced by oscillating water streams. In the Bailey process, the fibers of the fibrous batt are washed down and through the fibrous batt in order to entangle the fibers and form apertures in the fabric. U.S. Pat. No. 4,426,417 to Meitner et al., the disclosure of which is herein incorporated by reference, incorporated the use of thermoplastic meltblown during the formation of a fibrous batt as a means for attaining the loft for absorbency and maintain sufficient physical strength by bonding the fibers together. As the nature of the Meitner process is based upon the total and effective binding of the fibers to the thermoplastic meltblown there are potential issues with unbound or loosely bound fibers being disengaged from the meltblown.
Given the prior art attempt to form a non-linting, soft and yet strong absorbent materials, there remains a need for a nonwoven fabric exhibiting these characteristics and yet is formed in an expeditious and uncomplicated manner.
A method for forming a suitable nonwoven fabric meeting the aforementioned requirements has been identified in the application of fluidic energy such that a single fibrous batt is imparted with a highly entangled surface of outer fibers while retaining the loft and absorbency of a lightly entangled central layer of core fibers.
SUMMARY OF THE INVENTION
The present invention is directed to a method of forming a nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired.
In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a fibrous batt comprising a fibrous matrix. While use of natural fibers is common, the fibrous matrix may comprise synthetic fibers or blends of natural and synthetic fibers. The synthetic fibers are chosen from the group consisting of polyacrylates, polyolefins, polyamides, and polyesters and combinations thereof. Further, the synthetic fibers may comprise homogeneous, bicomponent, and/or multi-component profiles and the blends thereof.
In a particularly preferred form, the fibrous batt is carded and cross-lapped to form a fibrous batt. The fibrous batt is then continuously indexed through a station composed of a rotary foraminous surface and a fluidic manifold. Fluid streams from the fluidic manifold impinge upon the fibrous batt at a controlled energy level so as to integrate a portion of the overall fibrous content. The energy level is controlled such that the energy is sufficient to induce high levels of entanglement in the surface fibers, but has insufficient transmitted energy to induce high levels of entanglement of the inner fibers. A plurality of such stations can be employed whereby fluid streams are at the same or differing energy levels, impinging one or alternately both surfaces of the fibrous batt. The resulting differentially entangled nonwoven web exhibits a highly entangled fibrous outer surface and a lightly entangled fibrous core.
Subsequent to hydroentanglement, the present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, the disclosure of which is hereby incorporated by reference. In a typical configuration, the image transfer device may comprise a drum-like apparatus that is rotatable with respect to one or more hydroentangling manifolds.
It is within the purview of this invention that tension control means can be employed to further enhance the physical performance of the resulting lofty material.
A further aspect of the present invention is directed to a method of forming a nonwoven fabric which exhibits a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications. The fabric exhibits a high degree of loft and absorbency, thus permitting its use in those applications in which the fabric is applied as a cleaning wipe. Further, the material exhibits pleasant aesthetics, thus lending itself to application in medical applications.
A method of making the present durable nonwoven fabric comprises the steps of providing a fibrous matrix or batt, which is subjected to controlled levels of hydraulic energy. A homogeneous cotton fibrous batt has been found to desirably yield a fabric with soft hand and good absorbency. The fibrous batt is formed into a differentially entangled nonwoven fabric by the application of sufficient energy to entangle only the outer layers of the fibrous batt. Subsequently, the fabric can be passed over an image transfer device defined by three-dimensional elements against which the differentially entangled nonwoven fabric is forced during further application of further energy, whereby the fibrous constituents of the web are imaged and patterned by movement into regions between the three-dimensional elements of the transfer device.
It is within the purview of the present invention that physical property altering chemistries can be incorporated into the resulting differentially entangled fabric. Such chemistries include for example antimicrobial and anti-static agents which can be durably applied to the constituent fibers of the fibrous batt, to the fibrous batt during manufacture, and/or to the resulting fabric.
Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of an apparatus for manufacturing a differentially entangled nonwoven fabric, embodying the principles of the present invention; and
FIG. 2 is a diagrammatic view of five consecutive entangling sections and an image transfer station.
FIG. 3 is a cross-sectional view of a differentially entangled nonwoven fabric of the present invention, magnified at 20×; and
FIG. 4 is a cross-sectional view of the differentially entangled nonwoven fabric shown in FIG. 2 , magnified at 40×; and
FIG. 5 is a cross-sectional view of the differentially entangled nonwoven fabric shown in FIG. 3 , magnified at 10×, the upper and lower highly entangled surfaces having been pulled away from the lightly entangled central fibrous layer.
DETAILED DESCRIPTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
The present invention is directed to a method of forming nonwoven fabrics by hydroentanglement, wherein the outer surface of the fabric is substantially more entangled than the core layer. Hydroentanglement by this method is controlled by the application of fluidic energy such that the energy imparted into fibers of the fabric is sufficient to highly entangle only the outer fibers. The inner fibers are lightly entangled such that the overall structure is resistant to separation of the layers, yet retain much of the loftiness or bulk of the fibrous core layer that is responsible for tactile and ductile softness as well as absorbency. By advancing the fibrous batt with a relatively low tension through one or more entanglement stations, differential fiber entanglement is achieved, with the physical properties, both aesthetic and mechanical, of the resultant fabric being desirably achieved.
In accordance with a further aspect of the present invention, a nonwoven fabric can be produced which can be employed in medical applications such as undercast padding, with the fabric exhibiting sufficient strength, softness, drapeability, extensibility, and cushioning qualities. The level of entanglement of the nonwoven fabrics for this application may be controlled such that the level of entanglement of the surfaces is reduced so that the fibrous inner layer can retain further loft. In the alternative, the surface entanglement can be increased while retaining a somewhat reduced loftiness of the fibrous inner layer so that the surface layers are extremely resistant to linting. A material of this nature is found to have use in the graphic arts and lithography as it can be employed as a non-abrasive, absorbent wiper. It is within the scope of the present invention to control the level of entanglement in the resulting fabric to obtain materials with varying degrees of loft and linting performance.
Nonwoven fabrics are frequently produced using staple length fibers, the fabric typically has a degree of exposed surface fibers that will lint if not sufficiently retained into the structure of the fabric. The present invention provides a finished fabric that can be cut, processed or treated, and packaged for retail sale. The cost associated with forming and finishing steps can be desirably reduced.
With reference to FIG. 2 , therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous batt that typically comprises natural fibers, but may comprise synthetic staple fibers and natural/synthetic fiber blends. The fibrous batt is preferably carded and cross-lapped to form a fibrous batt, designated P. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. In this current embodiment, the fibrous batt has a draft ratio of approximately 2.5 to 1. U.S. Pat. No. 5,475,903, the disclosure of which is hereby incorporated by reference, illustrates a web drafting apparatus.
FIG. 2 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 02 upon which the fibrous batt P is positioned for pre-entangling by entangling manifold 01 into a wetted, lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′ sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 effecting entanglement of the web. Further entanglement of the web may be effected on the foraminous forming surface of a drum 20 by entanglement manifold 22 , with the web subsequently passed over successive foraminous drums 30 , 40 and 50 , for successive entangling treatment by entangling manifolds 32 , 42 and 51 . The total, optimal energy input to the fibrous batt to give the desired level of surface entanglement is in the range of about 0.027 to 0.046 hp-hr/lb.
The entangling apparatus of FIG. 2 may further include an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 61 , 62 , 63 and 64 , which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed. The total energy applied to the fibrous batt of the imaging manifolds is adjusted to maintain the energy input in the range of about 0.027 to 0.046 hp-hr/lb.
The present invention contemplates that the fibrous web P′ be advanced onto the moveable imaging surface of the image transfer device at a rate which is substantially equal to the rate of movement of the imaging surface. A J-box or scray can be employed for supporting the precursor web P′ as it is advanced onto the image transfer device to thereby minimize tension within the fibrous web. By controlling the rate of advancement of the fibrous batt P and the web P′ through the process so as to minimize, or substantially eliminate, tension within the web, differential hydroentanglement of the fibrous web is desirably effected.
FIG. 3 and FIG. 4 show a cross-section of a material produced by the present invention at 20× and 40× magnification, respectively. It should be noted that the “upper” and “lower” layers correspond to the highly entangled outer fibers of the fibrous batt.
FIG. 5 show a cross-section of the same material as depicted in FIG. 3 and FIG. 4 , whereby the outer highly entangled layers have been pulled apart from the lightly entangled central core fibers.
Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web preferably in the form of a natural and/or synthetic fibers, most preferably a cotton or cotton blend, which desirably provides good tactile and ductile softness and absorbency. During development, it was ascertained that fabric weights on the order of about 1 to 8 ounces per square yard, with the range of 2 to 5 ounces per square yard being most preferred, provided the best combination of softness, drapeability, absorbency, and durability.
EXAMPLES
Example 1
Using a forming apparatus as illustrated in FIG. 1 , a nonwoven fabric was made in accordance with the present invention by providing a fibrous batt comprising 100 weight percent cotton fiber. The fibrous batt had a basis weight of 3.3 ounces per square yard (plus or minus 7%). The fibrous web was 100% carded and cross-lapped, with a draft ratio of 2.5 to 1.
The fabric comprised 100 weight percent cotton as available from Barnhardt Manufacturing Company under code number RMC#2811. The fibrous batt was entangled by a series of entangling manifold stations such as diagrammatically illustrated in FIG. 1 and in greater detail in FIG. 2 . FIG. 2 illustrates disposition of fibrous batt P on a foraminous forming surface in the form of belt 02 , with the batt acted upon by a pre-entangling manifold 01 operating at 40 bar to form a wetted and lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′ sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 , operating at 40 bar, effecting entanglement of the web. The web then passes through a series of entangling stations comprising drums having foraminous forming surfaces, for entangling by entangling manifolds, with the web thereafter directed about the foraminous forming surface of a drum 20 for entangling by entanglement manifold 22 . The web is thereafter passed over successive foraminous drums 30 , 40 and 50 , with successive entangling treatment by entangling manifolds 32 , 42 and 51 . In the present examples, each of the entangling manifolds included 120 micron orifices spaced at 42.3 per inch, with manifolds 22 , 32 , 42 and 51 successively operated at 0, 50, 0, and 0 bar, with a line speed of 20 meters per minute. The total energy input into the fibrous batt is calculated to be 0.034 hp-hr/lb. A web having a trimmed width of 120 inches was employed.
Comparative Example
The comparative example is selected from a commercially available product in the form of Webril 100% Cotton Undercast Padding as available from the Kendall Company. This product is formed by compression forming cotton fiber during a mercerization process.
The accompanying Table 1 sets forth comparative test data for a fabric made by the present invention compared against a commercially available mercerized cotton fabric. Testing was done in accordance with the following test methods.
Test
Method
Basis weight (ounces/yd 2
ASTM D3776
Bulk (inches)
ASTM D5729
Tensiles MD and CD Grabs (lb/in)
ASTM D5034
Elongation MD and CD Grabs (%)
ASTM D5034
Tensiles MD and CD Strips (lb/in)
ASTM D5035
Elongation MD and CD Strips (%)
ASTM D5035
Absorbent capacity (%)
EDANA 10.3
Airborne particle shedding (Helmke drum)
IEST-RP-CC003.2*
*IEST-RP: Institute of Environmental Sciences and Technology Recommended Practice. The materials were cut in to samples measuring nominally 6 inches by 9 inches, and the unfinished edges were not sewn under before testing.
The physical test data for Example 1 and the Comparative Example are given in Table 1. The data in Table 1 show that the nonwoven fabric manufactured by the present invention has more uniform performance versus the comparative example when comparing the machine direction to the cross direction tensile and elongation properties. The materials were also tested for particle shedding. The material manufactured by the present invention exhibited a lower average number of particles shed for each of the particle sizes examined. For particle sizes less than or equal to 1 micron, the material manufactured by the current invention shed 2 to 3 times fewer particles.
From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
TABLE 1
Comparative
Physical Property
Units
Example 1
Example
Basis Weight
osy
3.3
3.1
Bulk
in
0.04
0.03
Strip Tensile - MD
lb./in.
1.1
1.5
Strip Tensile - CD
lb./in.
0.7
0.2
Combined Strip Tensile/Basis
0.5
0.5
Weight
Strip Elongation - MD
%
30.0
25.0
Strip Elongation - CD
%
73.8
80.6
Combined Strip Elongation/Basis
31.1
33.7
Weight
Grab Tensile - MD
lb./in.
4.4
2.5
Grab Tensile - CD
lb./in.
3.7
0.9
Combined Grab Tensile/Basis Weight
2.4
1.1
Grab Elongation - MD
%
45.0
34.0
Grab Elongation - CD
%
43.5
108.1
Combined Grab Elongation/Basis
26.5
42.5
Weight
Absorbent capacity
%
2000
1300
TABLE 2
Particles (×10 3 )/min/m 2
Particles
Particles
Particles
Particles
Particles
Particles
Sample
≧0.5 μm
≧0.7 μm
≧1.0 μm
≧2.0 μm
≧3.0 μm
≧5.0 μm
Example 1
37.9
32.5
26.3
16.1
9.9
5.4
(3.5)*
(2.6)
(2.3)
(1.6)
(1.2)
(0.9)
Comparative
99.9
76.1
52.0
24.2
13.2
6.8
Example
(28.8)
(22.3)
(15.7)
(8.1)
(4.6)
(2.6)
*Numbers in parentheses represent the standard deviation.
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The invention is directed to a hydroentangled nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Fabrics formed in accordance with the present invention exhibit a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications such as cast padding or orthopedic wraps.
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CROSS REFERENCE TO RELATED APPLICATION:
[0001] The present application is related to, and claims the priority of U.S. Provisional Patent Application Ser. No. 61/330,699, filed May 3, 2010, the entirety of which is incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the invention generally relate to communications networks and particularly to wireless communications networks, for example, Global System for Mobile Communications (GSM), the Universal Mobile Telecommunications System (UMTS), High Speed Packet Access (HSPA), and Evolved Universal Terrestrial Radio Access (EUTRA). More particularly, certain embodiments of the invention relate to methods, apparatuses, and computer program products for inter-radio access technology carrier aggregation mobility enhancement.
[0004] 2. Description of the Related Art
[0005] In order to deliver very high data throughputs to mobile nodes, the access networks may employ carrier aggregation and mobile nodes may receive and transmit on multiple component carriers, i.e., frequency bands. Carrier aggregation affects many functionalities in mobile networks, such as the mobility of mobile nodes and measurement reporting from mobile nodes.
[0006] Connected mode mobility, as discussed, for example, in 3GPP TS 36.331 V9.2.0 (2010 April), generally relates to a network node controlling the mobility of a mobile node during a radio resource control connection. The network node determines when the mobile node shall move to another cell, i.e., to another network node, which may be operating on another frequency or radio access technology. The network node triggers a handover procedure based, for example, on radio conditions, load capacity of the other network node, etc. To facilitate the handover procedure, the network node may configure the mobile node to perform measurement reporting that may include the configuration of measurement gaps. The network node may, in some conditions, blindly initiate handover of the mobile node to the other network node.
[0007] Inter-radio access technology (Inter-RAT) carrier aggregation has been utilized to enhance the rate of data transmission from one or more network nodes, for example, a long term evolution (LTE) eNodeB, a HSPA NodeB etc., to a mobile node, for example, user equipment.
[0008] Mobility of mobile nodes and handover procedures in systems employing Inter-RAT or Intra-RAT carrier aggregation may be based on measurement reports for a first component carrier available in a first network node, for example, a LTE node. Inter-radio access technology carrier aggregation may further include a second network node, for example, a HSPA node, as an additional downlink-only carrier. Mobility management and handover procedures of the mobile node during inter-radio access technology carrier aggregation may be primarily based on measurements results for the LTE carrier, and the mobility management for data of the HSPA carrier may directly follow the mobility and handover decisions obtained for the LTE carrier.
[0009] Problems may exist, however, if the optimal handover areas for the mobile node are different for the first and second network nodes, as illustrated in FIG. 1 . For example, the first and second network nodes may be operating at different frequencies (i.e., a LTE carrier operating at 1,800 or 2,600 MHz, while the HSPA carrier is operating at 2,100 MHz). In another example, the LTE carrier and the HSPA carrier may be using different antennas. In either of these two cases, the inter-radio access technology carrier aggregation will not provide the maximum data throughput to the mobile node. This may occur when the mobile node is not connected to the best serving HSPA network node that could provide the best radio link quality on the HSPA carrier between the HSPA network node and the mobile node. For example, a problem may be experienced with mobility management when the mobile node is approaching a site that provides HSPA radio access to mobile nodes, but does not provide LTE radio access to the mobile nodes. In such a case, measurement results obtained for the HSPA and LTE are uncorrelated and mobility and handover decisions for the HSPA carrier cannot be inferred from mobility and handover decisions for the LTE carrier. In such a case, the resulting total data rate is low as HSPA data is coming from another cell rather than the cell with the best link budget, and the LTE cell is also at a cell edge providing a low data rate.
[0010] Current inter-radio access technology carrier aggregation only involves the LTE carrier, and therefore measurement reporting is provided only for the LTE carrier. Inter-systems measurements are used when initiated by the system. Current inter-radio access technology carrier aggregation does not take into consideration measurement reporting for the other carriers, for example, the HSPA carrier.
SUMMARY
[0011] In accordance with an embodiment of the invention, there is provided an apparatus. The apparatus includes at least one processor, and at least one memory including computer program code. The at least one memory and the computer program code are configured to, with the at least one processor, cause the apparatus at least to receive a measurement reporting parameter from a first network node. The apparatus generates a measurement report based on the measurement reporting parameters and the one or more measured parameters of the signals received from the first network node and measured parameters received from the one or more second network nodes. The apparatus transmits the measurement report to the first network node, and receives a network mobility parameter from the first network node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on the one or more measured parameters obtained for at least one designated signal received from the first network node and parameters obtained for signals from the one or more second network nodes.
[0012] In accordance with an embodiment of the invention, there is provided a method. The method includes receiving, using a receiver, a measurement reporting parameter from a first network node. The method further includes measuring, using a processor, one or more parameters of signals received from a first network node and one or more second network nodes based on the measurement reporting parameter and generating a measurement report based on the one or more parameters. The method further includes generating, using the processor, a measurement report based on the measurement reporting parameters and the one or more measured parameters of the signals received from the first network node and the one or more parameters obtained for signals received from the one or more second network nodes. Further, the method includes transmitting, using a transmitter, the measurement report to the first network node, and receiving, using the receiver, a network mobility parameter from the first network node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on the one or more measured parameters obtained for at least one designated signal received from the first network node and one or more parameters obtained for signals received from the one or more second network nodes.
[0013] In accordance with an embodiment of the invention, there is provided another apparatus. The apparatus includes at least one processor, and at least one memory including computer program code. The at least one memory and the computer program code are configured to, with the at least one processor, cause the apparatus at least to transmit measurement reporting parameters to a mobile node. The apparatus receives a measurement report, based on the measurement reporting parameters, from the mobile node, wherein the measurement report comprises one or more parameters of signals received in the mobile node. Further, the apparatus transmits a network mobility parameter to the mobile node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on the one or more parameters obtained in the mobile node for at least one designated signal received from the apparatus and parameters obtained for signals received from one or more other network nodes, i.e. signals not received from the apparatus.
[0014] In accordance with an embodiment of the invention, there is provided another method. The method includes transmitting, using a transmitter, a measurement reporting parameter from a first network node to a mobile node. The method further includes receiving, in the first network node, using a receiver, a measurement report from the mobile node. Based on the measurement reporting parameters, the measurement report includes one or more parameters of signals received in the mobile node from the first network node and parameters obtained for signals received from one or more second network nodes. The method further includes transmitting, using the transmitter, a network mobility parameter to the mobile node based on the measurement report. The measurement reporting parameters includes report configuration information for configuring the measurement report based on the one or more parameters obtained in the mobile node for at least one designated signal received from the first network node and parameters obtained for signals received from the one or more second network nodes.
[0015] In accordance with an embodiment of the invention, there is provided a computer program product which may be executed in a mobile node and which is embodied on a computer readable storage medium. The computer program product is encoded with instructions to control a processor to perform a process. The process includes receiving, using a receiver, a measurement reporting parameter from a first network node. The process further includes measuring, using a processor, one or more parameters of signals received from the first network node and parameters of signals received from one or more second network nodes based on the measurement reporting parameters and generating a measurement report based on the one or more parameters. The process further includes generating, using the processor, a measurement report based on the measurement reporting parameters and the one or more measured parameters of the signals received from the first network node and parameters obtained for signals received from the one or more second network nodes. Further, the process includes transmitting, using a transmitter, the measurement report to the first network node, and receiving, using the receiver, a network mobility parameter from the first network node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on the one or more measured parameters obtained for at least one designated signal received from the first network node and parameters obtained for signals received from the one or more second network nodes.
[0016] In accordance with an embodiment of the invention, there is provided a computer program product which may be executed in a network node and which is embodied on a computer readable storage medium. The computer program product is encoded with instructions to control a processor to perform a process. The process includes transmitting, using a transmitter, a measurement reporting parameter from a first network node to a mobile node. The process further includes receiving, in the first network node, using a receiver, a measurement report from the mobile node. Based on the measurement reporting parameters, the measurement report includes one or more measured parameters of signals received in the mobile node from the first network node and parameters obtained for signals received in the mobile node from one or more second network nodes. The process further includes transmitting, using the transmitter, a network mobility parameter to the mobile node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on the one or more parameters obtained in the mobile node for at least one designated signal received in the mobile node from the first network node and parameters obtained for signals received in the mobile node one or more second network nodes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference will now be made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying drawings.
[0018] FIG. 1 illustrates different mobility requirements of an optimal cell change for a mobile node with a long term evolution carrier and a high speed packet access carrier of a conventional wireless communication system.
[0019] FIG. 2 illustrates measurements for inter-radio access technology carrier aggregation, in accordance with an embodiment of the invention.
[0020] FIG. 3 illustrates inter-radio access technology carrier aggregation, in accordance with another embodiment of the invention.
[0021] FIG. 4 illustrates an apparatus, in accordance with an embodiment of the invention.
[0022] FIG. 5 illustrates a method, in accordance with an embodiment of the invention.
[0023] FIG. 6 illustrates a method, in accordance with another embodiment of the invention.
[0024] FIG. 7 illustrates an apparatus, in accordance with an embodiment of the invention.
[0025] FIG. 8 illustrates a method, in accordance with an embodiment of the invention.
[0026] FIG. 9 illustrates a method, in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0027] It will be readily understood that the components of the invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus, the method, and the computer program product, as represented in the attached figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention.
[0028] For example, while the exemplary embodiments have been described above in the context of HSPA and LTE systems, it should be appreciated that the exemplary embodiments of this invention are not limited for use with this one particular combination of wireless communication systems, and that they may be used to advantage in other wireless communication systems and combinations of wireless communication systems.
[0029] If desired, the different functions discussed below may be performed in a different order and/or concurrently with each other. Furthermore, if desired, one or more of the above-described functions may be optional or may be combined. As such, the foregoing description should be considered as merely illustrative of the principles, teachings and embodiments of this invention, and not in limitation thereof
[0030] Embodiments of the invention are directed in particular to inter-RAT carrier aggregation, whereby measurement reports for the HSPA carrier are based on measurement reports obtained for the LTE carrier. According to an embodiment of the invention, when a mobile device receives a strong signal on the LTE carrier, and the transmission on the LTE carrier can sustain the necessary data rate, no measurement report for the HSPA carrier may be triggered, unless the received signal on the HSPA carrier of another cell is significantly stronger than the signal the mobile device receives on the LTE carrier.
[0031] According to another embodiment of the invention, when the mobile device receives a weak signal on the LTE carrier (i.e., only a low date rate achievable on the LTE carrier), a measurement report may be triggered when a new stronger signal on a HSPA carrier is detected.
[0032] FIG. 2 illustrates measurements for inter-radio access technology carrier aggregation, in accordance with an embodiment of the invention.
[0033] As illustrated in FIG. 2 , a LTE evolved Node B (LTE eNB) may transmit LTE reporting parameters (A) to the mobile node employing inter-RAT carrier aggregation. A typical reporting parameter such as handover hysteresis for LTE event A3 may be in a range of 1-3 dB. The eNB may transmit additional control parameters (A) for HSPA measurements to the mobile node. The hysteresis may be larger for the HSPA measurement reporting, for example, 3-6 dB. The objective of the settings of the inter-RAT measurement reporting is to provide information when measurement results obtained on the LTE carrier in a mobile node do trigger for inference measurement results on the HSPA carrier to be reported to the network. This may, for instance, happen when the mobile node is approaching a site with a network node which provides radio access for HSPA but not for LTE. Mobility and handover decisions based on measurement results obtained for the LTE carrier will in such a case not ensure that the mobile node is connected to the HSPA cell with the best signal quality.
[0034] As further illustrated in FIG. 2 , if the trigger condition for HSPA measurement reporting is met, the mobile node may send HSPA measurement reports to the LTE eNB (B) in addition to LTE measurement reports. The LTE eNB may utilize the received HSPA measurement reports to meet mobility and handover decisions for the mobile node employing LTE/HSPA carrier aggregation to enhance the data rate of the transmission to the mobile node.
[0035] FIG. 3 illustrates inter-radio access technology carrier aggregation, in accordance with another embodiment of the invention.
[0036] As illustrated in FIG. 3 , when the LTE carrier and HSPA carrier are operating in different frequencies, a mobile node employing inter-RAT carrier aggregation may, for instance, follow one of two routes.
[0037] Along the first route (Route 1), the mobile node may experience good signal quality on the LTE carrier, ensuring a sufficient data rate. Furthermore, the measurements in the mobile node along Route 1 will typically not indicate significant differences between the measurement results on the LTE and the HSPA carrier, since both sites, at the starting point and at the endpoint, provide radio access to LTE and HSPA. Therefore, no trigger condition for HSPA measurement reporting is met and the mobile node will only send measurement reports for the LTE carrier.
[0038] Along the second route (Route 2), mobility and handover decisions for the HSPA carrier may not be based on measurement reports obtained for the LTE carrier only, since the signal quality on the HSPA carrier in the proximity of the site supporting only radio access for HSPA can no longer be inferred from measurement reports obtained for the LTE carrier. Appropriate trigger conditions may be defined in such a case for HSPA measurement reporting in order to ensure that the mobile node along Route 2 is always connected to the HSPA cell providing the best signal quality or at least to a HSPA cell providing sufficient signal quality. Measurement reporting for the HSPA carrier may be triggered when the received signal on the LTE carrier is weak (i.e., allowing only a low data rate) and/or the received signal on a HSPA carrier is significantly stronger than the received signal on the LTE carrier.
[0039] In an embodiment of the invention, downlink throughput may be improved when the mobility decision can be based both on the LTE and the HSPA measurement reports. This improvement may occur when path loss values are different for different network nodes, i.e., for different base stations.
[0040] In this embodiment, the mobile node may be configured to employ carrier aggregation over at least two carriers. For example, the at least two carriers may include at least one LTE carrier and at least one HSPA carrier. A LTE carrier may be selected and may be configured to control the mobile node to measure and report parameters of the HSPA carrier(s). The criteria for HSPA measurement reporting may be based on the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the selected LTE carrier. For example, the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the selected LTE carrier may need to be below a predefined threshold level before the measurement reports for the HSPA carriers may be sent by the mobile node to the controlling network node (eNB) on the selected LTE carrier. The threshold may be predefined such that a reliable measurement reporting on the selected LTE carrier is still ensured.
[0041] In another scenario, the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the selected LTE carrier may need to be below the common pilot channel (CPICH) received signal code power (RSCP)/common pilot channel chip energy noise level (Ec/N0) of a HSPA carrier with a predefined margin before the measurement reports for the HSPA carrier may be sent by the mobile node to the controlling network node (eNB) on the selected LTE carrier.
[0042] In accordance with another embodiment of the invention, there is employed LTE carrier aggregation. In this embodiment, the mobile node may be configured to aggregate at least two LTE carriers. A first LTE carrier may be selected and may be configured to control the mobile node to measure and report parameters of at least one second LTE carrier. The criteria for measurement reporting on the at least one second LTE carrier may be based on the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the first LTE carrier. For example, the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the first LTE carrier may need to be below a threshold level before the measurement reports for the at least one second LTE carrier may be sent by the mobile node to the controlling network node (eNB).
[0043] In another scenario, the reference signal received power (RSRP)/reference signal received quality (RSRQ) of the first LTE carrier may need to be below a reference signal received power (RSRP)/reference signal received quality (RSRQ) level with a set margin of at least one of the at least one second LTE carriers before the measurement reports for the at least one second LTE carrier may be sent by the mobile node to the controlling network node (eNB).
[0044] In accordance with another embodiment of the invention, there is employed HSPA carrier aggregation. In this embodiment, the mobile node may be configured to aggregate at least two HSPA carriers. A first HSPA carrier may be selected and may be configured to control the mobile node to measure and report parameters of at least one second HSPA carrier. The criteria for measurement reporting on the at least one second HSPA carrier may be based on the common pilot channel received signal code power (RSCP)/common pilot channel chip energy noise level (Ec/N0) of the first HSPA carrier. For example, the common pilot channel received signal code power (RSCP)/common pilot channel chip energy noise level (Ec/N0) of the first HSPA carrier may need to be below a threshold level before the measurement reports for the at least one second HSPA carrier may be sent by the mobile node to the controlling network node (NB).
[0045] In another scenario, common pilot channel received signal code power (RSCP)/common pilot channel chip energy noise level (Ec/N0) of the first HSPA carrier may need to be below a common pilot channel received signal code power (RSCP)/common pilot channel chip energy noise level (Ec/N0) with a set margin of at least one of the at least one HSPA carriers before the measurement reports for the at least one second HSPA carrier may be sent by the mobile node to the controlling network node (NB).
[0046] FIG. 4 illustrates an apparatus, in accordance with certain embodiments of the invention. The apparatus 400 may include, for example, a mobile node or user equipment. The apparatus 400 may include a memory 410 including computer program code 420 . The computer program code 420 may be embodied on a computer readable non-transitory medium. The apparatus 400 may also include a processor 430 for processing information and executing instructions or operations. The memory 410 may be coupled to the processor 430 for storing information and instructions to be executed by the processor 430 . The computer program code 420 may be encoded with instructions to control the processor 430 to perform the method discussed below and illustrated in FIGS. 5 and 6 .
[0047] While a single memory 410 and a single processor 430 are illustrated in FIG. 4 , multiple memory and multiple processors may be utilized according to other embodiments.
[0048] Further, the apparatus 400 may be configured to communicate, using a transceiver 440 having a receiver portion 442 and a transmitter portion 444 , with a network node, for example, a base station, an evolved node B, or a high speed downlink packet access node (not illustrated). The apparatus 400 may further include an antenna 450 to communicate with the network node over a wireless link 460 , which may be a cellular radio link, for example, an inter-radio access technology link.
[0049] In accordance with certain embodiments of the invention, the receiver portion 442 may be configured to receive, via the antenna 450 over the wireless link 460 , a mobility and handover decision from a network node. The network node may include, for example, a LTE evolved node B carrier. The processor 430 may be configured to perform inter-radio access technology carrier aggregation based on the received mobility and handover decision from the network node.
[0050] When a strong LTE signal is present, the receiver portion 442 may be configured to receive the mobility and handover decision from the network node. A measurement report from a HSPA carrier may not be triggered, unless a received signal on a HSPA carrier of another cell is significantly stronger than the signal the apparatus 400 receives from the network node. Therefore, the processor 430 may be configured to perform inter-radio access technology carrier aggregation based solely on the mobility and handover decision from the network node based on measurement reports for the LTE signal.
[0051] However, when a HSPA signal from another network node, for example, a HSPA carrier, is significantly stronger than the LTE signal or when a weak LTE signal is present (i.e., only a low date rate is achievable on the LTE carrier), the receiver portion 442 may be configured to receive HSPA measurement reporting parameters to configure the apparatus 400 for measuring and reporting parameters of the HSPA carrier. The processor portion 430 may be configured to measure one or more measurement parameters from the HSPA carrier based on the measurement reporting parameters and to generate a measurement report of the one or more measurement parameters to be utilized for the inter-radio access technology carrier aggregation. The transmitter portion 444 may be configured to transmit, via the antenna 450 over the wireless link 460 , the measurement report from the HSPA carrier to the network node to be used for determining the mobility and handover decision of the network node. The receiver portion 442 may be configured to receive the mobility and handover decision from the network node. The processor 430 may be configured to perform inter-radio access technology carrier aggregation based on the mobility and handover decision from the network node.
[0052] In accordance with certain embodiments of the invention, the processor 430 may be configured to perform inter-radio access technology carrier aggregation of at least two carriers. The at least two carriers may include one of (1) at least one LTE carrier and at least one HSPA carrier, (2) at least two LTE carrier, and (3) at least two LTE high speed downlink packet access carriers, as discussed above.
[0053] FIG. 5 illustrates a method, in accordance with an embodiment of the invention. When a strong LTE signal is present, the method may include receiving, via the receiver portion 442 , a mobility and handover decision from the network node (step 510 ). A measurement report from a HSPA carrier may not be triggered, because the LTE carrier can sustain the needed data rate of the transmission. The method may further include performing, using the processor 430 , inter-radio access technology carrier aggregation based solely on the received mobility and handover decision from the network node based on measurement reports for the LTE signal (step 520 ).
[0054] FIG. 6 illustrates a method, in accordance with an embodiment of the invention. When a HSPA signal from another network node, for example, a HSPA carrier, is significantly stronger than the LTE signal or when a weak LTE signal is present (i.e., only a low date rate is achievable on the LTE carrier), the method may include receiving HSPA measurement reporting parameters from the network node to configure the apparatus 400 for measuring and reporting parameters of the HSPA carrier (step 610 ). The method may further include measuring, using the processor 430 , one or more measurement parameters from the HSPA carrier based on the measurement reporting parameters and generating a measurement report of the one or more measurement parameters to be utilized for the inter-radio access technology carrier aggregation (step 620 ). The method may include transmitting, via the transmitter portion 444 , the measurement report from the HSPA carrier to the network node to be used for determining the mobility and handover decision of the network node (step 630 ). The method may include receiving, via the receiver portion 442 , the mobility and handover decision from the network node (step 640 ). The method may include performing inter-radio access technology carrier aggregation based on the mobility and handover decision received from the network node based on measurement reports for the LTE signal (step 650 ).
[0055] In accordance with certain embodiments of the invention, the method may include performing inter-radio access technology carrier aggregation of at least two carriers. The at least two carriers may include one of (1) at least one LTE carrier and at least one HSPA carrier, (2) at least two LTE carriers, and (3) at least two HSPA carriers, as discussed above.
[0056] FIG. 7 illustrates an apparatus, in accordance with certain embodiments of the invention. The apparatus 700 may include, for example, a network node, for example, a LTE evolved node B. The apparatus 700 may include a memory 710 including computer program code 720 . The computer program code 720 may be embodied on a computer readable non-transitory medium. The apparatus 700 may also include a processor 730 for processing information and executing instructions or operations. The memory 710 may be coupled to the processor 730 for storing information and instructions to be executed by the processor 730 . The computer program code 720 may be encoded with instructions to control the processor 730 to perform the method discussed below and illustrated in FIGS. 8 and 9 .
[0057] While a single memory 710 and a single processor 730 are illustrated in FIG. 7 , multiple memory and multiple processors may be utilized according to other embodiments.
[0058] Further, the apparatus 700 may be configured to communicate, using a transceiver 740 having a receiver portion 742 and a transmitter portion 744 , with a mobile node, for example, user equipment (not illustrated). The apparatus 700 may further include an antenna 750 to communicate with the network node over a wireless link 760 , which may be a cellular radio link, for example, an inter-radio access technology link.
[0059] In accordance with certain embodiments of the invention, when a strong LTE signal is present, the transmitter portion 744 may be configured to transmit a mobility and handover decision to the mobile node. A measurement report from a HSPA carrier may not be triggered, because the apparatus 700 may be configured to sustain the needed data rate of the transmission. Therefore, inter-radio access technology carrier aggregation may be based solely on the received mobility and handover decision from the apparatus 700 based on measurement reports for the LTE signal.
[0060] However, when a HSPA signal from another network node, for example, a HSPA carrier, is significantly stronger than the LTE signal or when a weak LTE signal is present (i.e., only a low date rate is achievable on the LTE carrier), the transmitter portion 744 may be configured to transmit HSPA measurement reporting parameters to configure the mobile node for measuring and reporting parameters of the HSPA carrier. The receiver portion 742 may be configured to receive, via the antenna 750 over the wireless link 760 , a measurement report from the HSPA carrier through the mobile node to be used for determining the mobility and handover decision of the apparatus 700 . The transmitter portion 744 may be configured to transmit the mobility and handover decision from the apparatus 700 to the mobile node, whereby the mobile node performs inter-radio access technology carrier aggregation based on the mobility and handover decision from the apparatus 700 .
[0061] In accordance with certain embodiments of the invention, inter-radio access technology carrier aggregation may be performed on at least two carriers. The at least two carriers may include one of (1) at least one LTE carrier and at least one HSPA carrier, (2) at least two LTE carrier, and (3) at least two LTE high speed downlink packet access carriers, as discussed above.
[0062] FIG. 8 illustrates a method, in accordance with an embodiment of the invention. When a strong LTE signal is present, the method may include generating a mobility and handover decision (step 810 ). The method may further include transmitting, via the transmitter portion 742 , the mobility and handover decision from the apparatus 700 to the mobile node for performing inter-radio access technology carrier aggregation (step 820 ). A measurement report from a HSPA carrier may not be triggered, because the apparatus 700 can sustain the needed data rate of the transmission. Therefore, inter-radio access technology carrier aggregation may be performed based solely on the transmitted mobility and handover decision from the apparatus 700 based on measurement reports for the LTE signal.
[0063] FIG. 9 illustrates a method, in accordance with another embodiment of the invention. When a HSPA signal from another network node, for example, a HSPA carrier, is significantly stronger than the LTE signal or when a weak LTE signal is present (i.e., only a low date rate is achievable on the LTE carrier), the method may include transmitting, using the transmitter portion 744 , HSPA measurement reporting parameters to configure the mobile node for measuring and reporting parameters of the HSPA carrier (step 910 ). The method may further include receiving, via the receiver portion 742 , a measurement report from the HSPA carrier through the mobile node to be used for determining the mobility and handover decision of the apparatus 700 (step 920 ). The measurement report may include one or more parameters from the HSPA carrier that are based on the measurement reporting parameters. The method may include transmitting, via the transmitter portion 744 , the mobility and handover decision from the apparatus 700 to the mobile node, whereby the mobile node performs inter-radio access technology carrier aggregation based on the mobility and handover decision from the apparatus 700 (step 930 ).
[0064] In accordance with certain embodiments of the invention, inter-radio access technology carrier aggregation may be performed on at least two carriers. The at least two carriers may include one of (1) at least one LTE carrier and at least one HSPA carrier, (2) at least two LTE carrier, and (3) at least two LTE high speed downlink packet access carriers, as discussed above.
[0065] Further to the discussion above, it is to be understood that in an embodiment of the invention, the steps and the like may be changed without departing from the spirit and scope of the present invention. In addition, the methods described in FIGS. 5 , 6 , 8 and 9 may be repeated numerous times.
[0066] The memory 410 , 710 may be of any type suitable to the local technical environment and may be implemented using any suitable data storage technology, machine or computer readable storage medium, such as semiconductor-based memory devices, flash memory, magnetic memory devices and systems, optical memory devices and systems, fixed memory and removable memory, as non-limiting examples. The processors 430 , 730 may be of any type suitable to the local technical environment, and may include one or more of general purpose computers, special purpose computers, microprocessors, digital signal processors (DSPs), and processors based on multi-core processor architecture, as non-limiting examples.
[0067] A computer program code 420 , 720 according to certain embodiments of the invention, may be composed of modules that are in operative communication with one another, and which are designed to pass information or instructions to a communication device, such as the mobile node or the user equipment, a personal computer, a handheld device, such as a mobile, a cellular telephone, or a personal digital assistant (PDA) having wireless communication capabilities, a portable computer having wireless communication capabilities, an image capture device, such as a digital camera having wireless communication capabilities, a gaming device having wireless communication capabilities, a music storage and playback appliance having wireless communication capabilities, an Internet appliance permitting wireless Internet access and browsing, as well as a portable unit or a terminal that incorporates combinations of such functions.
[0068] The computer program code 420 , 720 may be configured to operate on a general purpose computer or an application specific integrated circuit (ASIC).
[0069] The computer readable non-transitory medium may include any media or means that can contain, store, communicate, propagate or transport the instructions for use by or in connection with an instruction execution system, apparatus, or device, for example, a disk media, computer memory, or other storage device. Non-transitory storage medium does not include a transitory signal. Examples of non-transitory storage medium include, for example, a computer-readable medium, a computer distribution medium, a computer-readable storage medium, and a computer program product.
[0070] The embodiments of the invention discussed above may be implemented by hardware, computer software executable by one or more of the processors 430 , 730 of the apparatus 400 and the apparatus 700 , respectively, or by a combination of hardware and software.
[0071] The software and/or hardware may reside on apparatus 400 , apparatus 700 , or other mobile communication devices. If desired, part of the software and/or hardware may reside on a apparatus 400 , part of the software and/or hardware may reside on a apparatus 700 , and part of the software and/or hardware may reside on other mobile communication devices. In an embodiment of the invention, software, or an instruction set may be maintained on any one of various conventional computer-readable media.
[0072] In accordance with an embodiment of the invention, there is provided a computer program product embodied on a computer readable storage medium. The computer program product is encoded with instructions to control a processor to perform a process. The process includes transmitting, using a transmitter, a mobility reporting parameter to a mobile node, and receiving, using a receiver, a measurement report from the mobile node. The measurement report includes one or more parameters of a network node that are based on the mobility reporting parameter. The process further includes transmitting, using the transmitter, a mobility parameter to the mobile node based on the measurement report.
[0073] One having ordinary skill in the art will readily understand that the invention as discussed above may be practiced with steps in a different order, and/or with hardware elements in configurations which are different than those which are disclosed. Therefore, although the invention has been described based upon these preferred and non-limiting embodiments, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions would be apparent, while remaining in the spirit and scope of the invention. Thus, the example embodiments do not limit the invention to the particular listed devices and technologies. In order to determine the metes and bounds of the invention, therefore, reference should be made to the appended claims.
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A method, apparatus, and computer program product are provided for inter-radio access technology carrier aggregation mobility enhancement. The apparatus receives a mobility reporting parameter from a first network node. The apparatus measures parameters of signals received from the first network node and one or more second network nodes based on the measurement reporting parameters. The apparatus generates a measurement report based on the measurement reporting parameters and the measured parameters of the signals, transmits the measurement report to the first network node, and receives a mobility parameter from the first network node based on the measurement report. The measurement reporting parameters include report configuration information for configuring the measurement report based on measured parameters obtained for designated signals received from the first network node and for signals received from the one or more second network nodes.
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FIELD OF THE INVENTION
[0001] This invention relates in general to optical systems and, more particularly, to techniques for optical power transfer control in optical systems.
BACKGROUND
[0002] In optical systems, there is often a need to regulate optical power. In one existing approach, a beam of radiation is expanded, collimated, and then routed through a variable density filter. The radiation exiting the filter is then collected and refocused to the output. The filter can be moved with respect to the beam. The position of the filter in relation to the beam determines the power transfer from the input to the output, which is a function of the density of the portion of the filter through which the beam is currently passing.
[0003] Although systems of this type has been generally adequate for their intended purposes, they have not be satisfactory in all respects. For example, a variable density filter is a relatively expensive component. In addition, a variable density filter will absorb some portion of the energy of the beam passing through it. The amount of energy absorbed depends on the density of the portion of the filter through which the beam is currently passing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] A better understanding of the present invention will be realized from the detailed description that follows, taken in conjunction with the accompanying drawing, in which:
[0005] FIG. 1 is diagrammatic fragmentary view of an optical apparatus that provides optical power transfer control, and that embodies aspects of the invention.
[0006] FIG. 2 is a diagrammatic side view of selected structure from the embodiment of FIG. 1 , including a disk, a motor shaft and an axis of rotation.
[0007] FIG. 3 is a diagrammatic fragmentary view of the apparatus of FIG. 1 , but showing the disk in a different operational position.
[0008] FIG. 4 is a diagrammatic view showing the end of an optical output fiber depicted in FIG. 1 , and showing how a beam of radiation moves in relation to the output fiber as the disk is rotated, the plane of FIG. 4 being coincident with the plane of an end surface of the output fiber.
[0009] FIG. 5 is a diagram showing the energy distribution that is present within a beam of radiation at the plane of the end surface of the output fiber.
[0010] FIG. 6 is diagrammatic fragmentary view of an optical apparatus that is an alternative embodiment of the optical apparatus of FIG. 1 , that provides optical power transfer control, and that embodies aspects of the invention.
[0011] FIG. 7 is a diagrammatic fragmentary view of the apparatus of FIG. 6 , but showing a different operational position.
DETAILED DESCRIPTION
[0012] FIG. 1 is diagrammatic fragmentary view of an optical apparatus 10 that provides optical power transfer control, and that embodies aspects of the invention. FIG. 1 is not completely to scale, for example in that some angles and distances have been exaggerated for clarity. The apparatus 10 includes two optical fibers 12 and 13 of a known type. The optical fiber 12 is an input fiber, and the optical fiber 13 is an output fiber. The apparatus 10 also includes two optical lenses 16 and 17 of a known type. The lens 16 is a collimating lens, and the lens 17 is an imaging lens. Further, the apparatus 10 includes a motor 21 having a shaft 23 that can rotate about an axis of rotation 24 . The motor 21 is controlled by a control circuit 22 . In the embodiment of FIG. 1 , the motor 21 is a stepper motor, but it could alternatively be any other suitable type of motor. Although the embodiment of FIG. 1 uses the motor 21 to rotate the shaft 23 , it would alternatively be possible to rotate the shaft 23 manually, or using any other suitable structure.
[0013] A circular optical disk 26 is fixedly mounted on the shaft 23 of the motor 21 , in a manner so that the axis of the circular disk 26 is coincident with the rotational axis 24 of the motor shaft 23 . FIG. 2 is a diagrammatic side view of the disk 26 , the motor shaft 23 and the axis 24 . The disk 26 has two planar side surfaces 31 and 32 on opposite sides thereof. The surfaces 31 and 32 form an angle 33 (σ) with respect to each other. Thus, in the side view of FIG. 1 , the disk 26 has a wedged-shaped appearance.
[0014] In the rotational position of the disk 26 that is shown in FIGS. 1 and 2 , the thickest portion of the disk is at the very top (at 45 in FIG. 2 ), and the thinnest portion is at the very bottom (at 46 in FIG. 2 ). In FIG. 2 , reference numeral 44 designates an imaginary line that is perpendicular to and intersects the axis of rotation 24 , and that passes through the thickest portion 45 and the thinnest portion 46 of the disk. As the disk 26 rotates, the imaginary line 44 rotates with the disk.
[0015] Incoming radiation exits the input fiber 12 and then travels to the collimating lens 16 . The lens 16 collimates the radiation from the input fiber 12 . The collimated radiation then travels from the lens 16 along a path of travel 51 to the disk 26 . Radiation propagating along the path of travel 51 impinges on the side surface 31 of the disk 26 at an initial angle of incidence 53 (θ 0 ) in relation to a line 49 perpendicular to the side surface 31 . This radiation enters the disk 26 through the side surface 31 , and then exits through the side surface 32 . As this radiation is passing through the disk 26 , it is refracted or redirected in a manner so that, after exiting the disk, it travels along a path of travel 52 that forms an angle 54 (δ) with respect to the path of travel 51 . Using Snell's law equations (applied in a two-dimensional sense), the relationship between the angles 33 (σ) and 54 (δ) is given by equation (1) below.
[0000]
δ
=
sin
-
1
(
n
disk
n
air
*
sin
{
sin
-
1
[
n
air
n
disk
*
sin
(
θ
0
)
]
-
σ
}
)
-
sin
-
1
(
n
disk
n
air
*
sin
{
sin
-
1
[
n
air
n
disk
*
sin
(
θ
0
)
]
}
)
(
1
)
[0000] where n air is the index of refraction of air, and n disk is the index of refraction of the disk 26 . For any rotational position of the disk 26 , equation (1) gives the deviation angle 54 (δ) as measured within a not-illustrated imaginary plane that contains line 51 and is parallel to line 44 . Within this imaginary plane, the deviation from line 51 to line 52 will always occur in a direction toward the thickest portion of the disk (as viewed within that not-illustrated imaginary plane).
[0016] After exiting the disk 26 , the beam of collimated radiation propagates along the path of travel 52 to the imaging lens 17 . The imaging lens 17 focuses this beam, and directs it approximately toward the output fiber 13 . Depending on the position of the disk 26 , this focused beam may or may not strike the end of the output fiber 13 , as discussed in more detail later. When the beam reaches a plane 61 that is coincident with the end of the output fiber 13 , the beam has a diameter or spot size given by equation (2) below.
[0000]
Spot
Size
=
4
μ
2
λ
f
π
D
,
(
2
)
[0000] where λ is wavelength, f is focal length of the lens 17 , D is the diameter of the beam at lens 17 , and μ 2 is a beam mode parameter.
[0017] As the disk 26 is rotated in relation to the other structure shown in FIG. 1 , there will be a progressive change in the thickness of the portion of the disk that refracts the radiation arriving from the lens 16 . In this regard, FIG. 3 is a diagrammatic fragmentary view that is identical to FIG. 1 , except that the disk 26 is shown in a different operational position. In particular, in FIG. 3 , the disk 26 has been rotated 180° from the position shown in FIG. 1 . The portion of the disk 26 influencing radiation from the lens 16 in FIG. 3 is significantly thinner than the portion of the disk influencing radiation in FIG. 1 . Consequently, the deviation angle 54 (δ) between the path of travel 51 and the path of travel 52 is smaller in FIG. 3 than in FIG. 1 . As a result, the beam of radiation leaving the disk 26 along the path of travel 52 will impinge on the imaging lens 17 at a different location than the beam of radiation in FIG. 1 . This in turn shifts the position of the focused beam traveling away from the lens 17 toward the output fiber 13 . Thus, for example, it will be noted in FIG. 1 that the focused beam from the lens 17 strikes the end of the fiber 13 , whereas in FIG. 3 the focused beam from the lens 17 misses the end of the output fiber 13 . This is discussed in more detail below, with reference to FIG. 4 .
[0018] FIG. 4 is a diagrammatic view in which the plane of the drawing is coincident with the plane 61 ( FIG. 1 ). FIG. 4 shows the end of the output fiber 13 , and shows how the beam of radiation moves in relation to the output fiber as the disk 26 rotates. With reference to FIG. 4 , the output fiber 13 has a typical configuration, including a cylindrical core 71 that is surrounded by a cylindrical sleeve 72 of cladding material. The broken-line circle 76 represents the location of the beam of radiation when the disk 26 is in the position shown in FIG. 1 . The broken-line circle 77 represents the location of the beam of radiation when the disk 26 is in the position shown in FIG. 3 . As the disk 26 is rotated, the beam moves along a circular path or travel 76 .
[0019] FIG. 5 is a diagram showing the energy distribution that is present in the beam of radiation at the plane 61 . In particular, the energy in the beam has an approximately Gaussian distribution 87 across a diameter 86 of the beam 76 . That is, the energy is strongest at the center of the beam, and drops off progressively in all radial directions from the center of the beam toward the edges of the beam. Thus, with reference to FIGS. 4 and 5 , when the beam is in the position shown at 76 in FIG. 4 , the central portion of the beam is centered on the core 71 of the output fiber 13 , and the output fiber 13 will be receiving a relatively high amount of energy from the beam.
[0020] If the disk 26 is then rotated, causing the beam to move away from the position 76 in either direction along the path of travel 79 , then the central portion of the beam will move away from the core 71 , and the core 71 will receive progressively less energy as the beam moves progressively farther from the position 76 toward the position 77 along the path of travel 79 . When the beam is in the position 77 , the core 71 of the fiber 13 will be receiving little or no energy from the beam. Thus, the coupling efficiency between the input fiber 12 and the output fiber 13 can be continuously varied by rotating the disk 26 .
[0021] FIG. 6 is diagrammatic fragmentary view of an optical apparatus 110 that is an alternative embodiment of the optical apparatus 10 of FIG. 1 , that provides optical power transfer control, and that embodies aspects of the invention. FIG. 7 is a diagrammatic fragmentary view that is identical to FIG. 6 , except that the disk 26 is shown in a different operational position. The apparatus 110 of FIGS. 5 and 6 is identical to the apparatus 10 of FIGS. 1-3 , except for the differences discussed below.
[0022] In the apparatus 110 of FIGS. 6-7 , the disk 26 is oriented so that the side surface 31 thereon is perpendicular to the axis of rotation of the shaft 23 of the motor 21 . In addition, the fiber 12 and the lens 16 are positioned so that the path of travel 51 is always perpendicular to the side surface 31 of the disk 26 , in all rotational positions of the disk. In the apparatus 10 of FIG. 1 , the initial angle of incidence 53 (θ 0 ) will vary. In contrast, in the apparatus 110 of FIGS. 6 and 7 , the initial angle of incidence will always be 0°, because the path of travel 51 is always perpendicular to the surface 31 . Substituting zero for θ 0 in equation (1) above, equation (1) simplifies down to equation (2) below:
[0000]
δ
=
sin
-
1
(
n
disk
n
air
*
sin
{
sin
-
1
[
n
air
n
disk
*
sin
(
0
)
]
-
σ
}
)
-
sin
-
1
(
n
disk
n
air
*
sin
{
sin
-
1
[
n
air
n
disk
*
sin
(
0
)
]
}
)
=
-
sin
-
1
(
n
disk
n
air
*
sin
{
σ
}
)
(
2
)
[0023] The optical disk 26 in the disclosed embodiments is significantly cheaper than a variable density filter of a type used to carry out optical power transfer in pre-existing systems. Moreover, such a pre-existing filter absorbs energy from the radiation passing through it, whereas the disk 26 does not.
[0024] In the disclosed embodiments, the disk 26 is rotated by the rotating shaft 23 of the motor 21 , under control of the control circuit 22 . However, it would alternatively be possible to omit the motor 21 and the control circuit 22 , and to manually adjust the position of the disk 26 . As still another alternative, it would be possible to replace the motor 22 with a not-illustrated linear motor, and to replace the disk 26 with a not-illustrated optical strip that is disposed in the converging beam rather than the collimated beam, the strip having a thickness that increases progressively in a direction lengthwise of the strip.
[0025] Although a selected embodiment has been illustrated and described in detail, it should be understood that a variety of substitutions and alterations are possible without departing from the spirit and scope of the present invention, as defined by the claims that follow.
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A method and apparatus involve: supporting an optical part for movement in relation to a first path of travel of radiation; moving the part successively to first and second positions in which radiation arriving along the first path of travel passes respectively through first and second sections of the part that provide respective different levels of refraction, the first and second sections causing radiation to thereafter travel along respective second and third paths of travel; and receiving at an output first and second portions of radiation respectively propagating along the second and third paths of travel, the first and second portions containing different amounts of optical energy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage Application of International Application No. PCT/EP2008/065271 filed Nov. 11, 2008, which designates the United States of America, and claims priority to German Application No. 10 2007 057 311.3 filed Nov. 28, 2007, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a method and a device for detecting faults in emission-relevant control devices in a vehicle, such as for example the injection of fuel into a cylinder.
BACKGROUND
[0003] At emission-relevant automotive control devices diverse methods of detecting faults are carried out for statutory reasons. On the one hand, many methods are a direct legal requirement and in most of these a fault has to be detected and the driver has to be alerted by means of a malfunction indication lamp if a specific emission limit is exceeded. At a data communication interface for the workshop codes, such as for example DTCs (diagnostic trouble codes), for each detected fault are made available in order to facilitate fault diagnosis.
[0004] In previous systems, such as are known from the background art, the fault detection of each individual method is independent of the fault detection of the other detection methods. For example, a problem regarding the injection quantity of an individual cylinder is only identified as an emission-relevant fault if this problem alone already results in the emission limit being reached. In other words, it is only when one of the cylinders exceeds the defined emission limit value that a fault is detected. If, however, the problem is less serious in terms of emission deterioration, then no emission-relevant fault is detected and/or communicated to the driver. If in the latter state there are further non-serious faults for example at one or more of the other cylinders, the overall system possibly exceeds emission limits but none of the individual methods detects an emission-relevant fault. In other words, in the situation where none of the individual cylinders exceeds the emission limit value but all of the cylinders combined exceed the emission limit value, this is not detected as a fault.
[0005] From DE 102 57 686 A1 moreover a method of adapting an injection characteristic is known. Here, an injection valve characteristic of an activated fuel injection valve that represents a reference injection behavior is adapted to ageing-related changes of an actual injection behavior. Here, during an operating state that requires no fuel injection, the injection valve is intermittently activated. In this case, at least one working cycle with activation precedes a working cycle without activation of the injection valve. In this case, in each case a rotational speed value of the internal combustion engine is detected for the working cycle with activation and at least one such value for the working cycles without activation. The difference of the detected values is then used to carry out a correction of the injection characteristic.
SUMMARY
[0006] According to various embodiments, a method and a device can be proposed that allow detection of a fault even when none of the subsystems per se exceeds a defined limit value.
[0007] According to an embodiment, a method of detecting faults in a plurality of emission-relevant control devices may comprise the steps: a) determine whether at least one parameter, which allows a conclusion to be drawn about the emission behavior of the respective control device, lies within a setpoint range, b) if the parameter lies outside of the setpoint range, a fault value that correlates with an emission increase is stored, c) if the parameter lies within the setpoint range, a fault value of zero is stored, d) wherein a total fault value is formed from all of the fault values of the control devices, and e) wherein a fault message is output if the total fault value exceeds a defined threshold value.
[0008] According to a further embodiment, in the step a) the parameter, if it lies outside of the setpoint range, may be first adapted in at least one adaptation cycle and then it is determined whether the parameter after the adaptation again lies outside of the setpoint range. According to a further embodiment, a fault code may be stored if in step b) it is determined that the parameter lies outside of the setpoint range, wherein the fault code characterizes the respective control device as faulty and/or wherein a fault code is stored if in step c) it is determined that the parameter lies within the setpoint range, wherein the fault code characterizes the respective control device as fault-free. According to a further embodiment, if the total fault value of the control devices reaches or exceeds the threshold value, wherein the threshold value may be for example an emission limit value, the fault codes may remain stored. According to a further embodiment, the emission-relevant control devices can be the cylinders of an engine of a vehicle. According to a further embodiment, as a parameter a fuel quantity that is injected into the respective cylinder can be determined. According to a further embodiment, the fuel quantity in the step a) can be injected with an injection time, wherein the injection time is an injection time for example of a preceding cycle, and then it is determined whether the fuel quantity lies within the setpoint range. According to a further embodiment, in the adaptation cycle the fuel quantity can be adapted at least by adjustment of the injection time and then it is determined afresh whether the fuel quantity lies within or outside of the setpoint range. According to a further embodiment, the fault value that correlates with the emission increase may be a scalar quantity. According to a further embodiment, the fault value may be zero if the fuel quantity lies within the setpoint range and the more the value deviates from the setpoint range the greater it becomes. According to a further embodiment, the total fault value can be the sum of the fault values of the individual control devices.
[0009] According to another embodiment, an arrangement for detecting faults in a plurality of emission-relevant control devices may comprise: a device for determining whether or not at least one parameter, which allows a conclusion to be drawn about the emission behavior of the respective control device, lies within a setpoint range, a memory device for storing a fault value, which correlates with an emission increase, if the parameter lies outside of the setpoint range and for storing a fault value of zero if the parameter lies within the setpoint range, and a device for determining a total fault value from all of the fault values of the control devices and for outputting a fault message if the total fault value exceeds a predetermined threshold value.
[0010] According to a further embodiment of the arrangement, an adaptation device can be provided, which adapts the parameter if said parameter lies outside of the setpoint range. According to a further embodiment of the arrangement, a memory code device for storing a fault code for the respective control devices can be provided, wherein the memory code device stores “faulty” as a fault code for a control device if the parameter lies outside of the setpoint range, and wherein the memory code device stores a “fault-free” fault code for a control device if the parameter lies within the setpoint range. According to a further embodiment of the arrangement, for example a warning light in a vehicle may flash if the device for determining the total fault value establishes that the total fault value exceeds the predetermined threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] There now follows a detailed description of various embodiments with reference to the accompanying drawings. These show in:
[0012] FIG. 1 a graph showing a fault function Y(X) in relation to a deviation of an injected fuel quantity MF (mass fuel) from a setpoint value according to an embodiment,
[0013] FIG. 2 a diagram of a first case, in which the injection time of a fuel quantity into a cylinder is adapted,
[0014] FIG. 3 a diagram of a second case, in which the injection time of a fuel quantity into a cylinder is adapted,
[0015] FIG. 4 a diagram of a third case, in which the injection time of a fuel quantity into a cylinder is adapted, and
[0016] FIG. 5 a diagram relating to the storage and evaluation of fault values and fault codes of the tested cylinders.
DETAILED DESCRIPTION
[0017] According to various embodiments, it is first determined whether at least one parameter, which directly and/or indirectly allows a conclusion to be drawn about the emission behavior of the respective control device, lies within a setpoint range. If the parameter lies outside of the setpoint range, a fault value that is correlated with an emission increase is stored. If the parameter lies within the setpoint range, on the other hand, zero is stored as a fault value. Subsequently, from all of the individual fault values a total fault value is determined. If this total fault value exceeds a defined threshold value, such as for example an emission limit value, a fault message is output.
[0018] This has the advantage that an exceeding of a threshold value is detected even if the individual control devices (subsystems) per se are still not affected by a fault serious enough that they alone already lead to an exceeding of the threshold value. Thus, the exceeding of for example an emission limit value may be detected, indicated to the driver and eliminated very much earlier.
[0019] In a further embodiment, in an adaptation cycle it is first tested whether the parameter may be corrected by conventional methods to such an extent that it reaches the setpoint range once more. If after the adaptation cycle the parameter lies once more within the setpoint range, then a fault value of zero is stored. If, however, after the adaptation cycle the parameter lies once more outside of the setpoint range, a fault value other than zero is stored. This has the advantage that a fault message is issued, not as soon as a parameter deviates from the defined setpoint range, but only when this parameter can no longer be corrected by conventional suitable measures. In this case, it is in principle conceivable that more than one, for example two or more adaptation cycles are carried out. If the parameter in the last adaptation cycle again lies outside of the setpoint range, then a corresponding fault value is stored.
[0020] In another embodiment, a fault code DTC (diagnostic trouble code) is stored if it is determined that the parameter lies outside of the setpoint range and/or after the adaptation cycle again lies outside of the setpoint range. In this case the fault code indicates that the respective control device is faulty. In addition, a fault code may also be stored if it is determined that the parameter lies within the setpoint range and/or after the adaptation cycle lies once more within the setpoint range, wherein the fault code then characterizes the respective control device as fault-free. Such a fault code DTC has the advantage that it may easily be read out for example in a workshop and supplies a mechanic with exact information about which of the control devices are faulty and which are working properly.
[0021] According to another embodiment, the fault codes remain stored if the total fault value of all subsystems reaches or exceeds the threshold value. The deletion of individual faults is suppressed for example until all of the subsystems have been tested. It is only if the total fault value of all of the subsystems lies below the threshold value that individual faults may be selectively deleted. This has the advantage that the quantity of stored data may be limited, namely to the cases where the total fault value for example actually equals or exceeds the threshold value.
[0022] In another embodiment, the emission-relevant control devices are the cylinders of a vehicle engine. In this case, the fuel quantity that is injected into the cylinders and burnt has an influence upon the emission behavior of the cylinders. For this reason, as a parameter the fuel quantity that is injected into the respective cylinder is determined and/or estimated. This has the advantage that the fuel quantity is a parameter that is relatively easy to estimate and to influence. The fuel quantity may be estimated for example by means of rotational speed sensors that are already present in a vehicle. However, other suitable sensors or combinations of sensors are in principle also conceivable for determining the fuel quantity.
[0023] In a further embodiment, the fuel quantity is first injected with an injection time that has been taken for example from the preceding cycle. It is then determined whether the fuel quantity lies within the setpoint range. This has the advantage that an injection time is used, which is already known and may for example have been optimized in the preceding cycle. This means moreover that the probability of the fuel quantity lying within the setpoint range at the first attempt is higher.
[0024] According to a further embodiment, the adaptation cycle is carried out on the basis of an injection time and the fuel quantity. In this case, as a suitable measure the injection time is correspondingly varied, within a setpoint range for the injection time, so that the fuel quantity as a parameter may be influenced in such a way that it is moved closer towards the setpoint range. If the fuel quantity subsequently lies once more within the setpoint range, then a fault value of zero may be stored. If however the fuel quantity lies once more outside of the setpoint range, then first of all there is a fault that cannot be corrected solely by means of the injection time, with the result that a fault value corresponding to the emission increase is defined. The adaptation cycle has the advantage that a fault value greater than zero and a corresponding fault code DTC indicating that the cylinder is faulty are not stored as soon as the fuel quantity deviates from a setpoint value. Instead, first the injection time is correspondingly varied. It is only if this is unsuccessful that the cylinder is assessed as faulty.
[0025] In a further embodiment, in the present case the fault value that is correlated with the emission increase is a scalar quantity. This has the advantage of allowing a total fault value and hence an exact emission increase to be determined in a very much more differentiated manner than if the information were restricted exclusively to whether a control device is faulty or fault-free. The fault value in this case is zero, if the fuel quantity lies within the setpoint range, or greater than zero, the more the value deviates from the setpoint range or setpoint value. The total fault value in this case is formed for example by the sum of all of the fault values of the individual control devices.
[0026] In FIG. 1 there is first represented a graph showing a fault function Y(X) as a function of a deviation of an injected fuel quantity MF (mass fuel) from a setpoint value.
[0027] In accordance with the method according to various embodiments the injected fuel quantity MF is regarded as a parameter for the occurrence of an emission increase, for example in a cylinder. In such a cylinder for example individual faults may occur, which may lead to faulty operating behavior and hence also to an emission increase. For example, over time the injection nozzle of the cylinder ages. In this case, the needle friction as well as the size of the injection nozzle may vary over time. A kind of coking of the injection nozzle and hence a narrowing thereof may moreover occur. Defects in actuating elements of the injection nozzle, for example in piezoelectric elements, may moreover arise.
[0028] If one considers the occurrence of faults with regard to a unit of a plurality of cylinders, then during operation variations in the output of the cylinders for example may arise. Furthermore, variations may arise in the fuel pressure sensors and/or FUP sensors and so on. The factors mentioned above are just a few examples of factors that influence the operating performance of cylinders and have a direct or indirect effect also upon the emission behavior.
[0029] For this reason, in addition to the fuel quantity MF a large number of further parameters or combinations of parameters that directly or indirectly allow a conclusion to be drawn about an emission increase are in principle conceivable. Such parameters also include parameters that relate for example to exhaust gas recirculation, turbocharging, exhaust gas after-treatment etc., to name but a few more examples. The absence of pre- and/or post-injections may moreover also be considered as a parameter.
[0030] According to various embodiments, with regard to the example of the fuel quantity, first a fuel quantity MF is injected with an injection time TI into a cylinder, wherein as injection time TI for example an injection time TI that was used in the preceding cycle is used. It is then determined and/or in a first estimation estimated whether the fuel quantity MF lies within the setpoint range (MF min , MF max ) or outside of the setpoint range. If the fuel quantity MF deviates from the setpoint range or alternatively from a setpoint value, then an adaptation cycle is started.
[0031] In this adaptation cycle the injection time TI is then adapted in accordance with the fuel quantity MF of the first estimation in order to achieve an improved and/or optimum fuel combustion. In this case, the injection time TI is adapted in such a way that the fuel quantity MF as far as possible achieves a defined setpoint value and/or is moved closer to this setpoint value. The fuel quantity MF is then estimated afresh after the injection operation with the new injection time TI. If the fuel quantity MF once again lies outside of the setpoint range and if the injection time TI cannot be adapted to such an extent that an optimum fuel combustion may be achieved because the injection time TI for the estimated fuel quantity that is needed for this purpose exceeds a maximum injection time TI max or is below a minimum injection time TI min , then a fault value is determined. This fault value is correlated with a corresponding emission increase. In principle, it is however also conceivable for a plurality of adaptation cycles to be executed before a fault value is stored in the last cycle because the fuel quantity once again lies outside of the setpoint range.
[0032] In the present case, FIG. 1 shows a graph representing an example of a fault function Y(X) for determining such a fault value. Here, the fault value is determined as a function of the deviation of the fuel quantity MF from a setpoint value. The deviation of the fuel quantity MF from the setpoint value is in this case an example of an indicator of the emission increase. From the graph it may be gathered that, if the deviation of the fuel quantity from the setpoint value still lies within a setpoint range and/or tolerance range, the fault value zero is set because in this case substantially no emission increase has yet been caused. Furthermore, a so-called fault code DTC is stored, which indicates that the cylinder is fault-free and which may be retrieved later for example in a repair workshop.
[0033] If however the deviation of the fuel quantity from the setpoint value lies outside of the setpoint range, then a fault value other than zero and/or greater than zero is set because in this case an emission increase arises at the tested cylinder. The magnitude of the fault value in the present case may be defined for example as a function of the magnitude of the deviation from the setpoint value or the setpoint range. Furthermore, a so-called fault code DTC (diagnostic trouble code) is stored, which indicates that the cylinder is faulty.
[0034] In the present case, the determined emission increase at this cylinder need not necessarily be already so great that an emission value reaches or exceeds a critical value, for example the emission limit. The crucial point is that in accordance with the method according to various embodiments it is determined that the cylinder in terms of its injection behavior is contributing towards an emission increase, wherein a correction solely for example by means of an adaptation cycle with the aid of the injection time TI is not possible.
[0035] According to various embodiments, subsystems, such as in the present case the cylinders, are considered in this manner.
[0036] The subsystems are in turn combined into an overall system, which in the present case comprises for example at least one or more or all of the cylinders of an engine. In this case, the fault codes of the individually considered cylinders and/or of the subsystems are combined and used to determine whether there is a fault with regard to the emission increase in the overall system.
[0037] In the following, with reference to FIGS. 2 to 4 three cases are distinguished in the context of the fault analysis according to various embodiments.
[0038] In FIG. 2 a diagram of a first case of an injected fuel quantity MF into a cylinder is represented. The diagram shows the setpoint range and a target setpoint value for the fuel quantity MF. The setpoint range is delimited here by a minimum fuel quantity MF min and a maximum fuel quantity MF max . First of all, fuel is injected with an injection time TI used for example in the last cycle and the injected fuel quantity MF is estimated in a first estimation. As the estimated fuel quantity MF lies within the setpoint range and has moved closer to the setpoint value, as is evident from FIG. 2 , no further adaptation of the injection time TI is necessary because a substantially optimum combustion has already been achieved. The existing injection time TI may be used again in the next cycle, in which the fuel quantity MF is estimated afresh. If this fuel quantity MF again lies within the setpoint range, then there is likewise no need for further adaptation of the injection time TI. If need be, a further adaptation may be effected to move the fuel quantity MF for example even closer to the setpoint value. This however has no influence upon the fault value in this case.
[0039] The fault value, which for example correlates with the emission increase, is therefore set at zero because the injection time TI and the associated fuel quantity MF lie within the setpoint range in order to realize an optimum combustion. The contribution of the considered cylinder (subsystem) to the fault sum of all of the considered cylinders (overall system) is therefore zero. Furthermore, a fault-free state is stored as a fault code DTC for this cylinder.
[0040] The second case, as represented in FIG. 3 , starts in the same way as the first case. First the fuel is injected with an injection time TI used for example in the last cycle and the injected fuel quantity MF is estimated in a first estimation. If the estimated fuel quantity MF deviates from the defined setpoint range, then the injection time TI is correspondingly adapted to the estimated fuel quantity MF in order to achieve a substantially optimum combustion. In the present case the fuel quantity MF in the first estimation lies below the minimum value MF min for the fuel quantity. A corresponding adaptation and/or correction of the injection time TI is therefore effected in order to achieve an optimum combustion. The adapted injection time TI is for example used again in the next cycle and the fuel quantity MF is estimated afresh. The estimated fuel quantity MF in this case again lies within the setpoint range. This means that in the present case an adaptation of the injection time TI as a measure was sufficient to correct the injected fuel quantity MF in such a way that it again falls within the defined setpoint range and a suitable combustion may be guaranteed.
[0041] The fault value that correlates with the emission increase is therefore set likewise at zero because an adaptation of the injection time TI is possible in order to realize a substantially optimum combustion. The contribution of the considered cylinder (subsystem) to the fault sum of all of the considered cylinders (overall system) is therefore likewise zero. Furthermore, there is stored as a fault code DTC that the cylinder is fault-free.
[0042] FIG. 4 then illustrates a third case. Here, as in the first and second case, first an injection time TI for example of a preceding cycle is used. Then the fuel quantity MF that was injected into the associated cylinder in the injection time TI is estimated. Here, according to FIG. 4 it emerges that the fuel injection quantity MF lies outside of the setpoint range, more precisely below the minimum permissible fuel quantity MF min . In this case a corresponding adaptation of the injection time TI is then effected. For the injection time TI there is likewise a permissible setpoint range, i.e. the injection time TI ranges between a minimum injection time TI min and a maximum injection time TI max . In the present case, therefore, for the adaptation to the estimated fuel quantity MF an injection time TI that lies within the defined setpoint range for the injection time is used, because the injection time TI cannot be varied and adapted arbitrarily. However, according to FIG. 4 it emerges that this injection time TI alone is insufficient to obtain an optimum combustion. The result of the adapted injection time TI is that the fuel quantity MF, which is subsequently estimated afresh, again lies outside of the setpoint range for the fuel quantity.
[0043] As a result of this, the fault value that was correlated with the emission increase is set for example to a value greater than zero. As already described above, the level of the fault value may be selected for example as a function of the extent to which the value for the fuel quantity MF lies outside of the setpoint range or deviates from the target setpoint value.
[0044] The reason why the fault value in the present third case, in contrast to the first and second case, is greater than zero is that here it is not possible to realize an optimum combustion by means of an adaptation of the injection time TI alone. Because, in this case too, the fuel quantity MF still lies outside of the setpoint range for the fuel quantity. The contribution of the considered cylinder (subsystem) to the fault sum of all of the considered cylinders (overall system) is therefore greater than zero. Furthermore, there is stored as a fault code DTC for this cylinder that it is faulty.
[0045] Alternatively it is also conceivable that, if after the first estimation or—in the case of a plurality of adaptation cycles—during the last estimations of the fuel quantity MF it is determined that a corrective injection time TI assigned for this purpose lies outside of the setpoint range for the injection time TI, a corresponding fault value is directly defined. In this case, a subsequent adaptation cycle is not executed once more to determine whether or not with an adapted injection time TI the fuel quantity MF lies outside of the setpoint range. Instead, as already mentioned, a fault value greater than zero is directly stored. This fault value may then for example be set in relation to the fictitious injection time TI that is needed to bring the fuel quantity MF back into the setpoint range. This fictitious injection time TI in the present case lies outside of the setpoint range for the injection time. The magnitude of the fault value may therefore be defined also as a function of the deviation of the injection time TI from its setpoint range or from a setpoint value.
[0046] All of the fault values or only the fault values greater than zero are saved in a memory device of the engine management system for example and are further processed there in order to determine an overall fault. For this purpose, the fault values may for example be summed to form an overall fault in the engine management system. Furthermore, the fault codes DTC are stored for example in a memory code device of the engine management system. A device for determining whether or not parameters, which allow a conclusion to be drawn about the emission behavior of the control devices, deviate from a setpoint range may comprise at least one or more suitable sensors and optionally an evaluation device. In the present case, for example at least one or more rotational speed sensors may be provided, the results of which may be used to determine and/or estimate a fuel quantity MF of a cylinder. The evaluation device for evaluating the results of the sensors may be a separate device or part of the engine management system. The additional adaptation device for carrying out measures to adapt one or more parameters, such as for example the injection time, may likewise be part of the engine management system or be at least controlled by the engine management system.
[0047] FIG. 5 shows a diagram illustrating the storage of the fault values and the fault codes DTC.
[0048] If with regard to the overall system it is determined that all of the considered cylinders (subsystems) have a fault value of zero because the fuel quantity MF either lies from the start within the setpoint range (case 1 ) or as a result of a corresponding adaptation of the injection time TI lies within the setpoint range (case 2 ), then an overall fault of zero is calculated. The fault code DTC for the respective cylinders, which are set as fault-free, may accordingly be deleted after all of the cylinders have been tested.
[0049] If it is then determined that there are already some cylinders that have a fault value greater than zero because the fuel quantity of these cylinders lies outside of the setpoint range and cannot be corrected by means of the injection time TI alone (case 3 ), it is checked whether the sum of the fault values is and/or remains less than 1. In this case, the associated fault codes DTC of the previously tested cylinders are initially not deleted. It is only if upon completion of the testing of all of the cylinders and/or subsystems it is determined that the fault value and/or in this case the total fault value is less than 1 that selectively all of the DTC fault codes may be deleted. In this case, the total emission increase of the cylinders (overall system) is still below an emission limit value.
[0050] If on the other hand it is determined that the cylinders ultimately have a total fault value of for example 1 or greater than 1, then the fault codes DTC of the individual cylinders are not deleted. Here it should be mentioned that, in contrast to the background art, the emission increase at a cylinder does not have be of such a magnitude that the cylinder on its own already leads to an exceeding of an emission limit value. The system according to various embodiments responds very much earlier, namely when each cylinder still does not exceed an emission limit value but all of the cylinders combined do.
[0051] In this case, a message indicating that an emission limit has been exceeded may be issued for example to the driver. For this purpose, for example a corresponding warning light in the vehicle may flash. The driver may then go to a workshop and a mechanic may determine from the stored fault codes DTC which cylinder is working properly and which cylinder is faulty.
[0052] At the same time, in the event of such an overall fault it is also possible for example for the pre-injection of all or some of the cylinders to be automatically suppressed by the engine management system in order to prevent an increase of the torque as a result of large pre-injections. Furthermore, a reduction of the torque as a result of the lack of a sufficient fuel quantity may be prevented. Post-injections/regeneration operations may moreover be suppressed in order to prevent too high and/or too low an exhaust gas temperature. These are however merely examples of measures that may be taken in the event that the total fault value is exceeded.
[0053] By virtue of the overall-system or subsystem consideration according to various embodiments of all of the fault detection methods it is possible for a fault to be already detected even if each individual fault does not yet lead to an exceeding of emissions. For this purpose, the individual fault detection methods supply, not logic information, such as for example fault “yes” or “no”, but a scalar quantity that is correlated with the emission increase in a subsystem. From the sum of all such quantities of the considered overall system or subsystem an exceeding of emissions is reliably detectable without an extreme individual case having to exist.
[0054] Because such an overall system fault is unsuitable as information for the workshop, the fault code DTC for each method involved in detection of the emission increase is supplied to a corresponding communication interface. As a result, the same information as before is available in the workshop.
[0055] It is moreover necessary to be able to identify an assured fault-free state of a system. For this it is not enough to know from a subsystem that its fault will not on its own lead to an exceeding of emissions. For this reason, according to various embodiments a subsystem is only reported as fault-free if either a) the emission rise caused by this subsystem is zero or b) all of the relevant subsystems have been tested and the total rise lies below the valid threshold value.
[0056] The various embodiments allow the detection of a fault in relation to the overall system or subsystem, in contrast to previous methods, in which only the emission influence of individual faults, i.e. faults of lower granularity, is considered.
[0057] In accordance with the method according to various embodiments, as already described above, for checking the injection quantity the deviation of the fuel quantity of each cylinder is considered. From each of these possible deviations an influence upon the total emissions of the system is calculated. The sum of all these values is used as a criterion for detection of a fault.
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A method and a device for identifying errors in emission-relevant control devices of a vehicle, such as the injection of fuel into a cylinder, allows error identification even if none of the sub-systems exceeds a predetermined threshold value. The method has the following steps: determining whether at least one parameter, which permits conclusions to be drawn about the emission behaviour of the respective control device, lies in a desired range; if the parameter lies outside said desired range, an error value that correlates to an increase in emissions is stored; if the parameter is in the desired range, an error value of zero is stored; a total error value is formed from all error values of the control device and an error message is output if the total error value exceeds a predetermined threshold value.
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This application is a continuation-in-part of application Ser. No. 12/423,044 filed Apr. 14, 2009.
FIELD OF THE INVENTION
The field of this invention is tools run downhole preferably on cable and which operate with on board power to perform a downhole function and more particularly wellbore debris cleanup.
BACKGROUND OF THE INVENTION
It is a common practice to plug wells and to have encroachment of water into the wellbore above the plug. FIG. 1 illustrates this phenomenon. It shows a wellbore 10 through formations 12 , 14 and 16 with a plug 18 in zone 16 . Water 20 has infiltrated as indicated by arrows 22 and brought sand 24 with it. There is not enough formation pressure to get the water 20 to the surface. As a result, the sand 24 simply settles on the plug 18 .
There are many techniques developed to remove debris from wellbores and a good survey article that reviews many of these procedures is SPE 113267 Published June 2008 by Li, Misselbrook and Seal entitled Sand Cleanout with Coiled Tubing: Choice of Process, Tools or Fluids? There are limits to which techniques can be used with low pressure formations. Techniques that involve pressurized fluid circulation present risk of fluid loss into a low pressure formation from simply the fluid column hydrostatic pressure that is created when the well is filled with fluid and circulated or jetted. The productivity of the formation can be adversely affected should such flow into the formation occur. As an alternative to liquid circulation, systems involving foam have been proposed with the idea being that the density of the foam is so low that fluid losses will not be an issue. Instead, the foam entrains the sand or debris and carries it to the surface without the creation of a hydrostatic head on the low pressure formation in the vicinity of the plug. The downside of this technique is the cost of the specialized foam equipment and the logistics of getting such equipment to the well site in remote locations.
Various techniques of capturing debris have been developed. Some involve chambers that have flapper type valves that allow liquid and sand to enter and then use gravity to allow the flapper to close trapping in the sand. The motive force can be a chamber under vacuum that is opened to the collection chamber downhole or the use of a reciprocating pump with a series of flapper type check valves. These systems can have operational issues with sand buildup on the seats for the flappers that keep them from sealing and as a result some of the captured sand simply escapes again. Some of these one shot systems that depend on a vacuum chamber to suck in water and sand into a containment chamber have been run in on wireline. Illustrative of some of these debris cleanup devices are U.S. Pat. No. 6,196,319 (wireline); U.S. Pat. No. 5,327,974 (tubing run); U.S. Pat. No. 5,318,128 (tubing run); U.S. Pat. No. 6,607,607 (coiled tubing); U.S. Pat. No. 4,671,359 (coiled tubing); U.S. Pat. No. 6,464,012 (wireline); U.S. Pat. No. 4,924,940 (rigid tubing) and U.S. Pat. No. 6,059,030 (rigid tubing).
The reciprocation debris collection systems also have the issue of a lack of continuous flow which promotes entrained sand to drop when flow is interrupted. Another issue with some tools for debris removal is a minimum diameter for these tools keeps them from being used in very small diameter wells. Proper positioning is also an issue. With tools that trap sand from flow entering at the lower end and run in on coiled tubing there is a possibility of forcing the lower end into the sand where the manner of kicking on the pump involves setting down weight such as in U.S. Pat. No. 6,059,030. On the other hand, especially with the one shot vacuum tools, being too high in the water and well above the sand line will result in minimal capture of sand.
What is needed is a debris removal tool that can be quickly deployed such as by slickline and can be made small enough to be useful in small diameter wells while at the same time using a debris removal technique that features effective capture of the sand and preferably a continuous fluid circulation while doing so. A modular design can help with carrying capacity in small wells and save trips to the surface to remove the captured sand. Other features that maintain fluid velocity to keep the sand entrained and further employ centrifugal force in aid of separating the sand from the circulating fluid are also potential features of the present invention. Those skilled in the art will have a better idea of the various aspects of the invention from a review of the detailed description of the preferred embodiment and the associated drawings, while recognizing that the full scope of the invention is determined by the appended claims.
One of the issues with introduction of bottom hole assemblies into a wellbore is how to advance the assembly when the well is deviated to the point where the force of gravity is insufficient to assure further progress downhole. Various types of propulsion devices have been devised but are either not suited for slickline application or not adapted to advance a bottom hole assembly through a deviated well. Some examples of such designs are U.S. Pat. Nos. 7,392,859; 7,325,606; 7,152,680; 7,121,343; 6,945,330; 6,189,621 and 6,397,946. US Publication 2009/0045975 shows a tractor that is driven on a slickline where the slickline itself has been advanced into a wellbore by the force of gravity from the weight of the bottom hole assembly.
U.S. Pat. No. 7,152,680 illustrates the use of a slickline run tool with self-contained power and control interface used in applications of inflating a packer or shooting a perforating gun.
SUMMARY OF THE INVENTION
A wellbore cleanup tool is run on slickline. It has an onboard power supply and circulation pump. Inlet flow is at the lower end into an inlet pipe that keeps up fluid velocity. The inlet pipe opens to a surrounding annular volume for sand containment and the fluid continues through a screen and into the pump for eventual exhaust back into the water in the wellbore. A modular structure is envisioned to add debris carrying capacity. Various ways to energize the device are possible. Other tools run on slickline are described such as a cutter, a scraper and a shifting tool. A motor driven by an onboard power supply operates the circulation pump as well as a vibration device to agitate the debris and prevent coring into the debris if compacted. A shroud presents an alternate flow path if the housing lower end is embedded in debris.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a plugged well where the debris collection device will be deployed;
FIG. 2 is the view of FIG. 1 with the device lowered into position adjacent the debris to be removed;
FIG. 3 is a detailed view of the debris removal device shown in FIG. 2 ;
FIG. 4 is a lower end view of the device in FIG. 3 and illustrating the modular capability of the design;
FIG. 5 is another application of a tool run on slickline to cut tubulars;
FIG. 6 is another application of a tool to scrape tubulars without an anchor that is run on slickline;
FIG. 7 is an alternative embodiment of the tool of FIG. 6 showing an anchoring feature used without the counter-rotating scrapers in FIG. 6 ;
FIG. 8 is a section view showing a slickline run tool used for moving a downhole component;
FIG. 9 is an alternative embodiment to the tool in FIG. 8 using a linear motor to set a packer;
FIG. 10 is an alternative to FIG. 9 that incorporates hydrostatic pressure to set a packer;
FIG. 11 illustrates the problem with using slicklines when encountering a wellbore that is deviated;
FIG. 12 illustrates how tractors are used to overcome the problem illustrated in FIG. 11 ;
FIG. 13 is an alternative embodiment to the debris removal tool shown in FIGS. 3 and 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 shows the tool 26 lowered into the water 20 on a slickline or non-conductive cable 28 . The main features of the tool are a disconnect 30 at the lower end of the cable 28 and a control system 32 for turning the tool 26 on and off and for other purposes. A power supply, such as a battery 34 , powers a motor 36 , which in turn runs a pump 38 . The modular debris removal tool 40 is at the bottom of the assembly.
While a cable or slickline 28 is preferred because it is a low cost way to rapidly get the tool 26 into the water 20 , a wireline can also be used and surface power through the wireline can replace the onboard battery 34 . The control system can be configured in different ways. In one version it can be a time delay energized at the surface so that the tool 26 will have enough time to be lowered into the water 20 before motor 36 starts running. Another way to actuate the motor 36 is to use a switch that is responsive to being immersed in water to complete the power delivery circuit. This can be a float type switch akin to a commode fill up valve or it can use the presence of water or other well fluids to otherwise complete a circuit. Since it is generally known at what depth the plug 18 has been set, the tool 26 can be quickly lowered to the approximate vicinity and then its speed reduced to avoid getting the lower end buried in the sand 24 . The control system can also incorporate a flow switch to detect plugging in the debris tool 40 and shut the pump 38 to avoid ruining it or burning up the motor 36 if the pump 38 plugs up or stops turning for any reason. Other aspects of the control system 32 can include the ability to transmit electro-magnetic or pressure wave signals through the wellbore or the slickline 28 such information such as the weight or volume of collected debris, for example.
Referring now to FIGS. 3 and 4 , the inner details of the debris removal tool 40 are illustrated. There is a tapered inlet 50 leading to a preferably centered lift tube 52 that defines an annular volume 54 around it. Tube 52 can have one or more centrifugal separators 56 inside whose purpose is to get the fluid stream spinning to get the solids to the inner wall using centrifugal force. Alternatively, the tube 52 itself can be a spiral so that flow through it at a high enough velocity to keep the solids entrained will also cause them to migrate to the inner wall until the exit ports 58 are reached. Some of the sand or other debris will fall down in the annular volume 54 where the fluid velocity is low or non-existent. As best shown in FIG. 3 , the fluid stream ultimately continues to a filter or screen 60 and into the suction of pump 38 . The pump discharge exits at ports 62 .
As shown in FIG. 4 the design can be modular so that tube 52 continues beyond partition 64 at thread 66 which defines a lowermost module. Thereafter, more modules can be added within the limits of the pump 38 to draw the required flow through tube 52 . Each module has exit ports 58 that lead to a discrete annular volume 54 associated with each module. Additional modules increase the debris retention capacity and reduce the number of trips out of the well to remove the desired amount of sand 24 .
Various options are contemplated. The tool 40 can be triggered to start when sensing the top of the layer of debris, or by depth in the well from known markers, or simply on a time delay basis. Movement uphole of a predetermined distance can shut the pump 38 off. This still allows the slickline operator to move up and down when reaching the debris so that he knows he's not stuck. The tool can include a vibrator 51 driven by a motor 53 to help fluidize the debris as an aid to getting it to move into the inlet 50 . The pump 38 can be employed to also create vibration by eccentric mounting of its impeller. The pump can also be a turbine style or a progressive cavity type pump.
The tool 40 has the ability to provide continuous circulation which not only improves its debris removal capabilities but can also assist when running in or pulling out of the hole to reduce chances of getting the tool stuck.
While the preferred tool is a debris catcher, other tools can be run in on cable or slickline and have an on board power source for accomplishing other downhole operations. FIG. 2 is intended to schematically illustrate other tools 40 that can accomplish other tasks downhole such as honing or light milling. To the extent a torque is applied by the tool to accomplish the task, a part of the tool can also include an anchor portion to engage a well tubular to resist the torque applied by the tool 40 . The slips or anchors that are used can be actuated with the on board power supply using a control system that for example can be responsive to a pattern of uphole and downhole movements of predetermined length to trigger the slips and start the tool.
FIG. 5 illustrates a tubular cutter 100 run in on slickline 102 . On top is a control package 104 that is equipped to selectively start the cutter 100 at a given location that can be based on a stored well profile in a processor that is part of package 104 . There can also be sensors that detect depth from markers in the well or there can more simply be a time delay with a surface estimation as to the depth needed for the cut. Sensors could be tactile feelers, spring loaded wheel counters or ultrasonic proximity sensors. A battery pack 106 supplies a motor 108 that turns a ball shaft 110 which in turn moves the hub 112 axially in opposed directions. Movement of hub 112 rotates arms 114 that have a grip assembly 116 at an outer end for contact with the tubular 118 that is to be cut. A second motor 120 also driven by the battery pack 106 powers a gearbox 122 to slow its output speed. The gearbox 122 is connected to rotatably mounted housing 124 using gear 126 . The gearbox 122 also turns ball screw 128 which drives housing 130 axially in opposed directions. Arms 132 and 134 link the housing 130 to the cutters 136 . As arms 132 and 134 get closer to each other the cutters 136 extend radially. Reversing the rotational direction of cutter motor 120 retracts the cutters 136 .
When the proper depth is reached and the anchor assemblies 116 get a firm grip on the tubular 118 to resist torque from cutting, the motor 120 is started to slowly extend the cutters 136 while the housing 124 is being driven by gear 126 . When the cutters 136 engage the tubular 118 the cutting action begins. As the housing 124 rotates to cut the blades are slowly advanced radially into the tubular 118 to increase the depth of the cut. Controls can be added to regulate the cutting action. They controls can be as simple as providing fixed speeds for the housing 124 rotation and the cutter 136 extension so that the radial force on the cutter 136 will not stall the motor 120 . Knowing the thickness of the tubular 118 the control package 104 can trigger the motor 120 to reverse when the cutters 136 have radially extended enough to cut through the tubular wall 118 . Alternatively, the amount of axial movement of the housing 130 can be measured or the number of turns of the ball screw 128 can be measured by the control package 104 to detect when the tubular 118 should be cut all the way through. Other options can involve a sensor on the cutter 136 that can optically determine that the tubular 118 has been cut clean through. Reversing rotation on motors 108 and 120 will allow the cutters 136 to retract and the anchors 116 to retract for a fast trip out of the well using the slickline 102 .
FIG. 6 illustrates a scraper tool 200 run on slickline 202 connected to a control package 204 that can in the same way as the package 104 discussed with regard to the FIG. 5 embodiment, selectively turn on the scraper 200 when the proper depth is reached. A battery pack 206 selectively powers the motor 208 . Motor shaft 210 is linked to drum 212 for tandem rotation. A gear assembly 214 drives drum 216 in the opposite direction as drum 212 . Each of the drums 212 and 216 have an array of flexible connectors 218 that each preferably have a ball 220 made of a hardened material such as carbide. There is a clearance around the extended balls 220 to the inner wall of the tubular 222 so that rotation can take place with side to side motion of the scraper 200 resulting in wall impacts on tubular 222 for the scraping action. There will be a minimal net torque force on the tool and it will not need to be anchored because the drums 212 and 216 rotate in opposite directions. In the alternative, there can be but a single drum 212 as shown in FIG. 7 . In that case the tool 200 needs to be stabilized against the torque from the scraping action. One way to anchor the tool is to use selectively extendable bow springs 224 that are preferably retracted for run in with slickline 202 so that the tool can progress rapidly to the location that needs to be scraped. Other types of driven extendable anchors could also be used and powered to extend and retract with the battery pack 206 . The scraper devices 220 can be made in a variety of shapes and include diamonds or other materials for the scraping action.
FIG. 8 shows a slickline 300 supporting a jar assembly 302 that is commonly employed with slicklines to use to release a tool that may get stuck in a wellbore and to indicate to the surface operator that the tool is in fact not stuck in its present location. The jar assembly can also be used to shift a sleeve 310 when the shifting keys 322 are engaged to a profile 332 . If an anchor is provided, the jar assembly 302 can be omitted and the motor 314 will actuate the sleeve 310 . A sensor package 304 selectively completes a circuit powered by the batteries 306 to actuate the tool, which in this case is a sleeve shifting tool 308 . The sensor package 304 can respond to locating collars or other signal transmitting devices 305 that indicate the approximate position of the sleeve 310 to be shifted to open or close the port 312 . Alternatively the sensor package 304 can respond to a predetermined movement of the slickline 300 or the surrounding wellbore conditions or an electromagnetic or pressure wave, to name a few examples. The main purpose of the sensor package 304 is to preserve power in the batteries 306 by keeping electrical load off the battery when it is not needed. A motor 314 is powered by the batteries 306 and in turn rotates a ball screw 316 , which, depending on the direction of motor rotation, makes the nut 318 move down against the bias of spring 320 or up with an assist from the spring 320 if the motor direction is reversed or the power to it is simply cut off. Fully open and fully closed and positions in between are possible for the sleeve 310 using the motor 314 . The shifting keys 322 are supported by linkages 324 and 326 on opposed ends. As hub 328 moves toward hub 330 the shifting keys 322 move out radially and latch into a conforming pattern 322 in the shifting sleeve 310 . There can be more than one sleeve 310 in the string 334 and it is preferred that the shifting pattern in each sleeve 310 be identical so that in one pass with the slickline 300 multiple sleeves can be opened or closed as needed regardless of their inside diameter. While a ball screw mechanism is illustrated in FIG. 8 other techniques for motor drivers such as a linear motor can be used to function equally.
FIG. 9 shows using a slickline 400 conveyed motor to set a mechanical packer 403 . The tool 400 includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit can be a linear motor, a motor with a power screw or any other similar arrangements. When motor is actuated, the center piston or power screw 408 which is connected to the packer mandrel 410 moves respectively to the housing 409 against which it is braced to set the packer 403 .
In another arrangement, as illustrated in FIG. 10 , a tool such as a packer or a bridge plug is set by a slickline conveyed setting tool 430 . The tool 430 also includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit 402 also can be a linear motor, a motor with a power screw or other similar arrangements. The center piston or power screw 411 is connected to a piston 404 which seals off using seals 405 a series of ports 412 at run in position. When the motor is actuated, the center piston or power screw 411 moves and allow the ports 412 to be connected to chamber 413 . Hydrostatic pressure enters the chamber 413 , working against atmosphere chamber 414 , pushing down the setting piston 413 and moving an actuating rod 406 . A tool 407 thus is set.
FIG. 11 illustrates a deviated wellbore 500 and a slickline 502 supporting a bottom hole assembly that can include logging tools or other tools 504 . When the assembly 504 hits the deviation 506 , forward progress stops and the cable goes slack as a signal on the surface that there is a problem downhole. When this happens, different steps have been taken to reduce friction such as adding external rollers or other bearings or adding viscosity reducers into the well. These systems have had limited success especially when the deviation is severe limiting the usefulness of the weight of the bottom hole assembly to further advance downhole.
FIG. 12 schematically illustrates the slickline 502 and the bottom hole assembly 504 but this time there is a tractor 508 that is connected to the bottom hole assembly (BHA) by a hinge or swivel joint or another connection 510 . The tractor assembly 508 has onboard power that can drive wheels or tracks 512 selectively when the slickline 502 has a detected slack condition. Although the preferred location of the tractor assembly is ahead or downhole from the BHA 504 and on an end opposite from the slickline 502 placement of the tractor assembly 508 can also be on the uphole side of the BHA 504 . At that time the drive system schematically represented by the tracks 512 starts up and drives the BHA 504 to the desired destination or until the deviation becomes slight enough to allow the slack to leave the slickline 502 . If that happens the drive system 512 will shut down to conserve the power supply, which in the preferred embodiment will be onboard batteries. The connection 510 is articulated and is short enough to avoid binding in sharp turns but at the same time is flexible enough to allow the BHA 504 and the tractor 508 to go into different planes and to go over internal irregularities in the wellbore. It can be a plurality of ball and socket joints that can exhibit column strength in compression, which can occur when driving the BHA out of the wellbore as an assist to tension in the slickline. When coming out of the hole in the deviated section, the assembly 508 can be triggered to start so as to reduce the stress in the slickline 502 but to maintain a predetermined stress level to avoid overrunning the surface equipment and creating slack in the cable that can cause the cable 502 to ball up around the BHA 504 . Ideally, a slight tension in the slickline 502 is desired when coming out of the hole. The mechanism that actually does the driving can be retractable to give the assembly 508 a smooth exterior profile where the well is not substantially deviated so that maximum advantage of the available gravitational force can be taken when tripping in the hole and to minimize the chances to getting stuck when tripping out. Apart from wheels 512 or a track system other driving alternatives are envisioned such a spiral on the exterior of a drum whose center axis is aligned with the assembly 508 . Alternatively the tractor assembly can have a surrounding seal with an onboard pump that can pump fluid from one side of the seal to the opposite side of the seal and in so doing propel the assembly 508 in the desired direction. The drum can be solid or it can have articulated components to allow it to have a smaller diameter than the outer housing of the BHA 504 for when the driving is not required and a larger diameter to extend beyond the BHA 504 housing when it is required to drive the assembly 508 . The drum can be driven in opposed direction depending on whether the BHA 504 is being tripped into and out of the well. The assembly 510 could have some column strength so that when tripping out of the well it can be in compression to provide a push force to the BHA 504 uphole such as to try to break it free if it gets stuck on the trip out of the hole. This objective can be addressed with a series of articulated links with limited degree of freedom to allow for some column strength and yet enough flexibility to flex to allow the assembly 508 to be in a different plane than the BHA 504 . Such planes can intersect at up to 90 degrees. Different devices can be a part of the BHA 504 as discussed above. It should also be noted that relative rotation can be permitted between the assembly 508 and the BHA 504 which is permitted by the connector 510 . This feature allows the assembly to negotiate a change of plane with a change in the deviation in the wellbore more easily in a deviated portion where the assembly 508 is operational.
FIG. 13 illustrates a wellbore tubular 600 having perforations 602 above a plug 604 . Debris 606 has accumulated above the plug 604 and well fluids 608 extend to level 610 . A slickline 612 supports the tool assembly 614 for running into and out of the wellbore tubular 600 . Onboard power is provided through a battery pack 616 . A control module 618 is adjacent the battery pack 616 and is responsive to an input signal for operation of motor 620 . The signal can be movement patterns of the slickline 612 for example and the effect of the signal can relate to on and off functioning of the motor 620 or control of its speed or both, for examples. A pump module 622 includes a pump 624 and an oscillator 626 that preferably run on a common shaft 628 . Arrows 630 represent discharge flow from the pump 622 that moves downhole as further represented by arrows 632 . Optionally, a baffle or diverter 634 can be used to ensure that the pumped flow represented by arrows 630 heads in the downhole direction toward inlet 636 . A shield 638 surrounds the housing 640 while leaving an annular gap 642 in between. Gap 642 is open at the top 644 and closed at the bottom 646 . Holes 648 in the housing 640 lead from the annular gap 642 to the inlet 636 . Holes 648 can optionally have screens in them. The shield allows pump circulation even if the lower end 646 gets implanted in the debris 606 such as when the assembly 614 is lowered at high speed with the slickline 612 and unexpectedly lands in the debris while still moving fairly fast. The shield 638 can be as tall as a meter so that circulation can still be established with the lower end 646 buried in debris 606 .
The debris and flow that carries it enter at the lower end into inlet 636 . From there the velocity picks up in inlet tube 649 that has outlets that comprise spiral paths as illustrated by 650 so that the rapidly moving slurry has a radial component imparted to it so that debris 652 can be positioned over annular space 654 when its velocity decreases and as a result the debris 652 settles by gravity into space 654 . The fluid stream without the settled debris continues moving up through a filter 656 and then into the pump inlet 658 .
The modular feature of FIG. 4 can also be incorporated into the design of FIG. 13 to increase the volume of the debris collection annular space 654 .
The vibration device 626 is schematically illustrated. The frequency and amplitude of the vibrations generated can be varied using the motor 620 . Although a single motor is shown driving both the pump 624 and the vibration device 626 , they can be independently driven for tandem or independent operation.
The closed bottom on shield 638 gives the assembly 614 a bigger footprint so that it is less likely to penetrate into the debris 606 when advanced at a high speed into the wellbore. The shield 638 is but the preferred embodiment for a technique for allowing an alternate flow path if the lower end 646 is buried in debris for flow to keep moving and enter the inlet 636 .
The deflector 634 is optional and will not be required if the path of least resistance to fluid flow is downhole and through the tool assembly 614 . This can occur when the well fluid level 610 is sufficiently further away from the pump 624 than the lower end 646 .
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 wellbore cleanup tool is run on slickline. It has an onboard power supply and circulation pump. Inlet flow is at the lower end into an inlet pipe that keeps up fluid velocity. The inlet pipe opens to a surrounding annular volume for sand containment and the fluid continues through a screen and into the pump for eventual exhaust back into the water in the wellbore. A modular structure is envisioned to add debris carrying capacity. Various ways to energize the device are possible. Other tools run on slickline are described such as a cutter, a scraper and a shifting tool. A motor driven by an onboard power supply operates the circulation pump as well as a vibration device to agitate the debris and prevent coring into the debris if compacted. A shroud presents an alternate flow path if the housing lower end is embedded in debris.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to the printing and dyeing industry in the textile industry, and more particularly relates to a printing paste containing polysaccharide, sodium L-pyrrolidonecarboxylate and an etherified starch, a printing colorant containing the printing paste, and preparation methods of the printing paste and the printing colorant.
2. Related Art
In recent years, the principal component of a printing paste mainly contains, for example, starch, modified starch and sodium alginate. For example, the principal component of printing pastes disclosed in CN101314920A (Chinese Patent Application No. CN200810047683.0, publication date: Dec. 3, 2008, Composite printing paste for active dry and preparation method thereof), and CN1563558A (Chinese Patent Application No. 200410014343.X, publication date: Jan. 12, 2005, Composite denatured starch printing paste with adjustable viscosity, and preparation method and application thereof), is modified starch. The principal component of printing pastes disclosed in CN1600983A (Chinese Patent Application No. 03151285.2, publication date: Mar. 30, 2005, Printing paste and preparation method thereof), and CN1436891A (Chinese Patent Application No. 02110072.1, publication date: Aug. 20, 2003, Active dye printing paste and preparation method thereof), is formed by combining a carboxymethyl starch and sodium alginate. Although starch, dyes and printing and dyeing chemicals have good stability, the application of starch in printing is restricted due to poor rheological properties. However, when sodium alginate meets calcium ions or other metal ions in hard water, calcium alginate or alginates of other metals are generated and precipitated, and due to thus precipitates, carboxyl ions losses charges. Therefore, a secondary alcohol group=CHOH in sodium alginate paste may react with the dye, which not only damages the colorant performance, but also causes chromatic aberration due to unstable coloring, as well as influence the color fastness; moreover, sodium alginate is expensive, so the cost of the paste is high.
Consequently, people continue to develop printing pastes that do not use starch and sodium alginate as the principal component, for example, inorganic printing paste with montmorillonite powder or rectorite clay as the principal component (see CN1095120A (Chinese Patent Application No. 93105604.7, publication date: Nov. 16, 1994, Inorganic printing paste and production method), and CN1072976A (Chinese Patent Application No. 92101281.0, publication date: Jun. 9, 1993, Preparation and application of rectorite clay printing paste)); printing pastes with guar gum or xanthan gum as the main raw material (see CN1844558A (Chinese Patent Application No. 200610038915.7, publication date: Oct. 11, 2006, Guar gum silk printing paste and preparation method thereof), and CN1116670A (Chinese Patent Application No. 94110684.5, publication date: Feb. 14, 1996, Printing paste and production method thereof); and printing pastes with a galactomannan as the principal component (see CN1050419A (Chinese Patent Application No. 89107422.8, publication date: Apr. 3, 1991, Sesbania seed gum printing paste and preparation process thereof), and CN1922357A (Chinese Patent Application No. 200580005243.3, publication date: Feb. 28, 2007, Thickening agent for textile printing paste). However, theses paste are applicable in direct printing processes such as a rotary screen printing process and a flat screen printing process, but not applicable in cold transfer printing process.
In cold transfer printing, first a suitable printing colorant containing a paste and a dye is printing on a paper, to form a transfer printing paper with desired patterns or letters; next, a surface of the transfer printing paper with the dye is tightly combined with a fabric to be printed, and then the dyes is removed or peeled off from the paper by means of a pressure, and the patterns or letters on the transfer printing paper is transferred onto the fabric. CN1939946A (Chinese Patent Application No. 200610116181.X, publication date: Apr. 4, 2007, Production method of modified paste and printing colorant), discloses a cold transfer printing paste synthesized by polymerization of starch, vinyl acetate and acrylic acid, but the rheological property of the modified starch formed through graft copolymerization is poor, and the colorant prepared by the paste is sensitive to shear force, so that the viscosity of the colorant is lost when being continuously printed on a transfer paper surface at a high speed and during the transfer printing process, which influences the quality of printing.
Therefore, there is a need for a novel paste for cold transfer printing and printing colorant containing the paste that can overcome one or more disadvantages of the paste or colorants in the prior art.
SUMMARY
The present invention is directed to a novel paste and colorant for cold transfer printing.
The inventor of the present invention accidentally finds that, a paste obtained by combining polysaccharide, sodium L-pyrrolidonecarboxylate and an etherified starch as the principal component and a printing colorant formulated by the paste have one or more of the following advantages: good rheological properties, good printing characteristics, good washing and coating performance, uniform dispersion of components, being stable (for example, being stable to metal ions), low cost, stable quality of printing and high color fastness. The present invention is developed based on the fmdings.
In a first aspect of the present invention, a paste for cold transfer printing is provided, which contains polysaccharide, sodium L-pyrrolidonecarboxylate, an etherified starch and water.
In an implementation of the first aspect of the present invention, the polysaccharide is xanthan gum, guar gum or a mixture thereof.
In another implementation of the first aspect of the present invention, the polysaccharide is 0.5 wt % to 4 wt % based on the total weight of the paste. In a specific implementation, the polysaccharide is 0.5 wt % to 3.5 wt % , 0.5 wt % to 3 wt % , 0.5 wt % to 2.5 wt % , 0.5 wt % to 2 wt %, 1 wt % to 4 wt %, 1.5 wt % to 4 wt %, 2 wt % to 4 wt %, 1 wt % to 3.5 wt %, 1 wt % to 3 wt %, 1 wt % to 2.5 wt % or 1 wt % to 2 wt %, based on the total weight of the paste.
In another implementation of the first aspect of the present invention, the sodium L-pyrrolidonecarboxylate is 0.4 wt % to 3 wt % based on the total weight of the paste. In a specific implementation, the sodium L-pyrrolidonecarboxylate is 0.4 wt % to 2.5 wt %, 0.4 wt % to 2 wt %, 0.5 wt % to 3 wt %, 1 wt % to 3 wt %, 0.5 wt % to 2.5 wt %, 0.5 wt % to 2 wt %, 1 wt % to 2.5 wt % or 1 wt % to 2 wt %, based on the total weight of the paste.
In another implementation of the first aspect of the present invention, the etherified starch is a low-viscosity etherified starch, of which the efflux time is 30 s or less detected by using a Zahn cup #2 at 25° C.
In another implementation of the first aspect of the present invention, the etherified starch is 20 wt % to 45 wt % based on the total weight of the paste. In a specific implementation, the etherified starch is 20 wt % to 40 wt %, 20 wt % to 35 wt %, 20 wt % to 30 wt %, 25 wt % to 45 wt %, 30 wt % to 45 wt %, 35 wt % to 45 wt %, 22 wt % to 40 wt %, 22 wt % to 35 wt %, 25 wt % to 35 wt % or 25 wt % to 30 wt %, based on the total weight of the paste.
In another implementation of the first aspect of the present invention, the water is distilled water, double distilled water, re-distilled water or deionized water.
In another implementation of the first aspect of the present invention, the paste contains:
polysaccharide
0.5 wt % to 4 wt %,
sodium L-pyrrolidonecarboxylate
0.4 wt % to 3 wt %,
an etherified starch
20 wt % to 45 wt %, and
water
added to 100 wt %.
In another implementation of the first aspect of the present invention, the paste contains:
polysaccharide
1 wt % to 2 wt %,
sodium L-pyrrolidonecarboxylate
0.5 wt % to 2 wt %,
an etherified starch
25 wt % to 30 wt %, and
water
added to 100 wt %.
In a second aspect of the present invention, a preparation method of the paste of the first aspect of the present invention is provided, which includes the following steps:
a) in a mixer, at a temperature of 65° C. to 70° C. (for example, about 70° C.), and at 1400 to 2800 r/min, stirring a mixture of a formula amount of polysaccharide and a suitable amount of water for 1 to 5 hrs (for example, about 2 hrs),
b) slowly adding a formula amount of sodium L-pyrrolidonecarboxylate with stirring, and mixing uniformly, to obtain a colloid pre-paste for use;
c) stirring a mixture of a formula amount of an etherified starch and a suitable amount of water in a reactor, and heating with stirring to raise the temperature of the mixture, after the temperature is raised to 80° C. to 90° C. (for example, about 85° C.), stopping heating, and stirring at a rotation rate of 1200 to 1600 r/min (for example, about 1400 r/min), for 1 to 5 hrs (for example, about 2 hrs), to obtain a light gray transparent starch pre-paste for use; and
d) mixing the colloid pre-paste obtained in Step b), and the starch pre-paste obtained in Step c), adding water to a certain volume, and stirring uniformly at 10° C. to 35° C. (fore example, about room temperature). The finally product obtained through the above steps is the cold transfer printing paste.
In an implementation of the second aspect of the present invention, the raw materials each independently have the characteristics described in the first aspect of the present invention.
In a third aspect of the present invention, a printing colorant is provided, which includes the paste of the first aspect of the present invention, an active dye, a defoamer, a flatting agent, a pH stabilizer and water.
In an implementation of the third aspect of the present invention, the paste is as described in any implementation of the first aspect of the present invention. In different implementations of the third aspect of the present invention, the paste of the first aspect of the present invention is each independently combined with other components in the printing colorant.
In another implementation of the third aspect of the present invention, the paste is 20 wt % to 30 wt % based on the total weight of the printing colorant. In a specific implementation, the paste is 20 wt % to 25 wt %, 20 to 26 wt %, 20 wt % to 25 wt %, 22 wt % to 30 wt %, 24 wt % to 30 wt %, 25 wt % to 30 wt %, 21 wt % to 29 wt %, 22 wt % to 28 wt %, 23 wt % to 27 wt % or 24 wt % to 26 wt %, based on the total weight of the printing colorant.
In another implementation of the third aspect of the present invention, the active dye may be conventionally used dye in the art. In a specific implementation, the active dye is selected from KN type active dyes, M type active dyes, Dystar Remazol series dyes, P type active dyes (such as products of Huntsman International LLC.) and so on.
In another implementation of the third aspect of the present invention, the active dye is 15 wt % to 35 wt % based on the total weight of the printing colorant. In a specific implementation, the active dye is 15 wt % to 32 wt %, 15 wt % to 30 wt %, 15 wt % to 28 wt %, 15 wt % to 25 wt %, 18 wt % to 35 wt %, 20 wt % to 35 wt %, 22 wt % to 35 wt %, 25 wt % to 35 wt %, 18 wt % to 30 wt %, 18 wt % to 28 wt % or 20 wt % to 25 wt %, based on the total weight of the printing colorant.
In another implementation of the third aspect of the present invention, the defoamer may be a conventionally used defoamer in the art. In a specific implementation, the defoamer is selected from tributyl phosphate, polyorganosiloxane, polyester modified siloxane or a combination thereof.
In another implementation of the third aspect of the present invention, the defoamer is 0.3 wt % to 0.5 wt % based on the total weight of the printing colorant. In a specific implementation, the defoamer is 0.3 wt % to 0.48 wt %, 0.3 wt % to 0.45 wt %, 0.3 wt % to 0.42 wt %, 0.3 wt % to 0.4 wt %, 0.32 wt % to 0.5 wt %, 0.35 wt % to 0.5 wt %, 0.38 wt % to 0.5 wt % or 0.4 wt % to 0.5 wt %, based on the total weight of the printing colorant.
In another implementation of the third aspect of the present invention, the flatting agent may be conventionally used flatting agent in the art. In a specific implementation, the flatting agent is selected from polyether modified polydimethyl siloxane, polyether modified methyl alkyl polysiloxane or a combination thereof.
In another implementation of the third aspect of the present invention, the flatting agent is 0.2 wt % to 0.6 wt % based on the total weight of the printing colorant. In a specific implementation, the flatting agent is 0.2 wt % to 0.55 wt %, 0.2 wt % to 0.5 wt %, 0.2 wt % to 0.45 wt %, 0.25 wt % to 0.6 wt %, 0.3 wt % to 0.6 wt %, 0.35 wt % to 0.6 wt %, 0.4 wt % to 0.6 wt %, 0.25 wt % to 0.55 wt % or 0.3 wt % to 0.5 wt %, based on the total weight of the printing colorant.
In another implementation of the third aspect of the present invention, the pH stabilizer may be a conventionally used pH stabilizer in the art. In a specific implementation, the pH stabilizer is selected from sodium dihydrogen phosphate, disodium hydrogen phosphate or a combination thereof.
In another implementation of the third aspect of the present invention, the pH stabilizer is 0.5 wt % to 1.5 wt % based on the total weight of the printing colorant. In a specific implementation, the pH stabilizer is 0.5 wt % to 1.25 wt %, 0.5 wt % to 1.0 wt %, 0.55 wt % to 1.5 wt %, 0.6 wt % to 1.5 wt %, 0.55 wt % to 1.25 wt % or 0.6 wt % to 1.0 wt %, based on the total weight of the printing colorant.
In another implementation of the third aspect of the present invention, the water is distilled water, double distilled water, re-distilled water or deionized water.
In another implementation of the third aspect of the present invention, the printing colorant contains:
the paste of the first aspect
20 wt % to 30 wt %,
of the present invention
an active dye
15 wt % to 35 wt %,
a defoamer
0.3 wt % to 0.5 wt %,
a flatting agent
0.2 wt % to 0.6 wt %,
a pH stabilizer
0.5 wt % to 1.5 wt %, and
water
added to 100 wt %.
In another implementation of the third aspect of the present invention, the printing colorant contains:
the paste of the first aspect
24 wt % to 26 wt %,
of the present invention
an active dye
20 wt % to 25 wt %,
a defoamer
0.3 wt % to 0.4 wt %,
a flatting agent
0.3 wt % to 0.5 wt %,
a pH stabilizer
0.6 wt % to 1.0 wt %, and
water
added to 100 wt %.
The printing colorant of the third aspect of the present invention further contains a solvent for dissolving the active dye. In an implementation, the solvent for dissolving the active dye is ethylene glycol monobutyl ether. In an implementation, the amount of the solvent for dissolving the active dye can be easily determined by persons of ordinary skill in the art based on the existing knowledge and/or experience. In an implementation, the solvent for dissolving the active dye, the amount of the solvent is a minimum amount required for dissolving the active dye.
The printing colorant of the third aspect of the present invention further contains a viscosity modifier (for example, ethylene glycol), and/or surface tension modifier (for example, diethylene glycol). In an implementation, the viscosity modifier may be not limited and, for example, adjust the viscosity of the material to 1000 to 1300 centipoise at 25° C. In an implementation, the surface tension modifier may be not limited and, for example, adjust the surface tension of the material to ≧40 dyne.
In a fourth aspect of the present invention, a preparation method of the printing colorant of the third aspect of the present invention is provided, which includes the following steps:
i) pre-dissolving a dye in water, and added a solvent (for example, ethylene glycol monobutyl ether), till the dye is completely dissolved;
ii) to the solution obtained in Step i), adding the paste of the first aspect of the present invention, a flatting agent, a defoamer and a pH stabilizer, and stirring uniformly (for example, for 45 to 60 min at a stirring speed of 1200 to 1480 r/min);
iii) to the material obtained in Step ii), adding a viscosity modifier (for example, ethylene glycol), to adjust the viscosity to 1000 to 1300 centipoise at 25° C., to obtain a crude colorant; and
iv) grinding the crude colorant (for example, in a ball mill for 2 hrs), to a particle diameter, to enable the colorant to pass through a 200-mesh sieve; and then adjusting the surface tension to ≧40 dyne by using a surface tension modifier (for example, diethylene glycol), to obtain a printing colorant.
In a fifth aspect of the present invention, a cold transfer printing method is provided, which includes a step of using the paste of any implementation of the first aspect of the present invention and the printing colorant of any implementation of the third aspect of the present invention.
The aspects of the present invention and features thereof are further described below.
All the references cited in the present invention are incorporated herein by reference in their entire, and when the meaning expressed by the references is not consistent with that expressed by the present invention, the expression in the present invention is taken as a criterion. In addition, unless otherwise defined herein, the various terms and phrases used in the present invention have the common meaning known to persons of ordinary skill in the art, and if the meaning of terms and phrases defined herein is not consistent with the known meaning, the expression in the present invention is taken as a criterion.
The term “paste for cold transfer printing” in the present invention (also referred to as “cold transfer printing paste”), refers to a paste involved in printing and dyeing industry, and is applicable in a cold transfer printing production process. Similarly, the term “printing colorant” (also referred to as “colorant for printing”), refers to a slurry containing a dye involved in the printing and dyeing industry, and is applicable in a printing production process, especially a cold transfer printing production process.
The term “polysaccharide” in the present invention refers to a type of large carbohydrate substances having a complex molecular structure formed by a plurality of monosaccharide molecules through a condensation reaction with the loss of water. All the carbohydrate compounds meeting the polymer compound concept and derivatives thereof belong to polysaccharides. The commonly used polysaccharide includes starch; glycogen; cellulose structure; chitin (chitosan): a straight chain formed by N-acyl-D-glucosamine connected with (1,4)glycosidic linkages; synanthrin: a polyfructose, existing in compositae roots; and agar. Preferably, the polysaccharide useful in the present invention mainly includes xanthan gum and guar gum.
The term “etherified starch” in the present invention (also referred to as starch ether), is a starch replaced ether formed by a reaction of the hydroxyl group in the starch molecule and a reactive substance. Preferably, the etherified starch useful in the present invention is a low-viscosity etherified starch, namely, an etherified starch of which the efflux time is 30 s or less detected by using a Zahn cup #2 at 25° C.
The unit symbol “wt %” in the present invention refers to a percentage calculated by weight.
The term “flatting agent” in the present invention refers to a commonly used printing and dyeing additive, which enables a colorant to form a flat, smooth and uniform film in the drying and film forming process.
The term “pH stabilizer” in the present invention refers to a pH buffer, which can impede changes of the pH value of a solution, so that the pH value of the system is stable in a certain range.
In an implementation of the present invention, a cold transfer printing paste is provided, which is prepared by polysaccharide, sodium L-pyrrolidonecarboxylate, an etherified starch and distilled water.
In an implementation, the weight percentages of the components of the cold transfer printing paste are as follows:
polysaccharide
0.5% to 4%,
sodium L-pyrrolidonecarboxylate
0.4% to 3%,
an etherified starch
20% to 45%, and
distilled water
added to 100%.
In an implementation, the polysaccharide is xanthan gum or guar gum.
In an implementation of the present invention, a preparation method of a cold transfer printing paste, which includes the following steps:
A) in distilled water, placing polysaccharide of 0.5% to 4% of the total weight of a cold transfer printing paste in a mixer, stirring for 2 hrs at a temperature of 70° C. and at 1400 to 2800 r/min, slowly adding sodium L-pyrrolidonecarboxylate of 0.4% to 3% of the total weight of a cold transfer printing paste with stirring, and mixing uniformly, to obtain a colloid pre-paste for use;
B) in distilled water, placing a low-viscosity etherified starch of 20% to 45% of the total weight of a cold transfer printing paste in a reactor, heating with stirring at a slow speed, after the temperature is raised to 850° C., stopping heating, and stirring the resulting product for 2 hrs at a rotation speed of 1400 r/min, to obtain a starch pre-paste for use, where the whole paste is light gray and transparent; and
C) mixing the colloid pre-paste with the starch pre-paste, adding distilled water to 100%, and stirring uniformly at room temperature, to obtain a cold transfer printing paste.
In an implementation, xanthan gum, guar gum and sodium L-pyrrolidonecarboxylate are industrial grade. In an implementation, the starch is an industrial grade low-viscosity etherified starch, of which the efflux time is 30 s or less detected by a Zahn cup #2 at 25° C.
In another implementation of the present invention, a printing colorant containing the cold transfer printing paste of the present invention is provided.
In a specific implementation, the components of the printing colorant are:
the cold transfer printing paste
20% to 30%,
an active dye
15% to 35%,
a defoamer
0.3% to 0.5%,
a flatting agent
0.2% to 0.6%,
a pH stabilizer
0.5% to 1.5%, and
deionized water
added to 100%.
In an implementation of the present invention, a preparation method of a printing colorant is provided, which includes the following steps: in deionized water, pre-dissolving a dye, and adding ethylene glycol monobutyl ether till the dye is completely dissolved; next, adding the cold transfer printing paste, a flatting agent, a defoamer and a pH stabilizer and stirring for 45 to 60 min at a stirring speed of 1200 to 1480 r/min; adding ethylene glycol to adjust the viscosity of the colorant to 1000 to 1300 centipoise at 25° C., to obtain a crude colorant; grinding the resulting crude colorant for about 2 hrs in a ball mill to a particle diameter, to enable the colorant to pass through a 200-mesh sieve, and then adjusting the surface tension to ≧40 dyne by using diethylene glycol, to obtain the printing colorant.
In an implementation, the active dye is a KN type active dye or an M type active dye (made in China); or a Dystar Remazol series dye; or a P type active dye (manufactured by Huntsman International LLC.).
In an implementation, the xanthan gum useful in the present invention is industrial grade, and is a type of natural polysaccharide and important biopolymer, and is produced by cabbage black rot Xanthomonas campestris pv. Campestris with carbohydrates as main raw materials by adopting an aerobic fermentation bioengineering technology.
In an implementation, the guar gum useful in the present invention is industrial grade, and is a macromolecular natural hydrophilic colloid, and is mainly formed by polymerization of galactose and mannose and belongs to natural galactomannans.
In an implementation, sodium L-pyrrolidonecarboxylate useful in the present invention is industrial grade. L-pyrrolidone carboxylic acid (PCA) is one of the decomposition products of filamentous assembly protein. Sodium L-pyrrolidonecarboxylate is a sodium salt of PCA, has a chemical name of sodium 2-pyrrolidone-5-carboxylate (PCA-Na), is generated from sodium L-glutamate through heating cyclization or in the presence of microorganisms, and is a biomimetic compound.
In an implementation, the low-viscosity etherified starch useful in the present invention is industrial grade, has strong stability, is not easily aged, and will not be hydrolyzed and precipitated; and has a strong adhesion and a good permeability, is not easily decoated, and has good film-forming properties.
The cold printing paste and the printing colorant of the present invention have many advantages, and are suitable for a cold transfer printing production process. The cold transfer printing paste has stable physical properties, and the formulated printing colorant has good printing performance and transfer performance. The viscosity of the paste will not be reduced in use, and the pasted can be removed by washing the textile after transfer printing with an extremely small amount of water. During cold print-batch fixation, the dye is fixed into the fiber without influences, the printed patterns are fine, the quality is excellent, and the cost is low.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given herein below for illustration only, and thus not limitative of the present invention wherein:
FIG. 1 is a flow chart of a process of formulating a cold transfer printing paste; and
FIG. 2 is a flow chart of a process of formulating a printing colorant.
DETAILED DESCRIPTION
The present invention is further described below with the following embodiments, but the scope of the present invention is not limited to the following embodiments. Persons skilled in the art can understand that, without departing from the spirit and scope of the present invention, various changes and modifications can be made to the present invention.
In the following embodiments, unless otherwise stated, the components are known in the art and are commercially available. In addition, unless otherwise stated, % represents, wt %, namely, weight percentage.
I Common Preparation Method of Cold Transfer Printing Paste
Herein, common preparation method of a cold transfer printing paste of the present invention is described with a preferable implementation and an exemplary implementation.
The weight percentages of components of the cold transfer printing paste are as follows:
polysaccharide
1% to 2%,
sodium L-pyrrolidonecarboxylate
0.5% to 2%,
an etherified starch
25% to 30%, and
distilled water
added to 100%.
Polysaccharide is xanthan gum or guar gum.
A common synthesis method of the cold transfer printing paste is as follows:
FIG. 1 shows a flow chart of a common process of formulating a cold transfer printing paste. Specifically, in distilled water, polysaccharide of 1% to 2% of the total weight of a cold transfer printing paste is placed in a mixer, and stirred for 2 hrs at a temperature 70° C. and 1400 to 2800 r/min, and sodium 2-pyrrolidone-5-carboxylate (PCA-Na), of 0.5% to 2% of the total weight of a cold transfer printing paste is slowly added with stirring, and mixed uniformly, to obtain a colloid pre-paste for use. In distilled water, a low-viscosity etherified starch (for example, a low-viscosity etherified starch manufactured by Shanghai Kangpai Biological Technology Co., Ltd.), of 25% to 30% of the total weight of a cold transfer printing paste is placed in a reactor, and heated with stirring at a low speed. After the temperature is raised to 85° C., heating is stopped, and the mixture is stirred for 2 hrs at a rotation speed of about 1400 r/min, to obtain the starch pre-paste, where the whole paste is light gray and transparent. The colloid pre-paste and the starch pre-paste are mixed at room temperature, and distilled water is added to 100%, and the mixture is stirred uniformly, to obtain a cold transfer printing paste.
Embodiment 1 Preparation of Cold Transfer Printing Paste
Formula components are:
xanthan gum
2%,
sodium L-pyrrolidonecarboxylate
1%,
an etherified starch
28%, and
distilled water
added to 100%.
As for the preparation method, reference can be made to the flow chart of formulating a cold transfer printing paste shown in FIG. 1 . Specifically, in distilled water, xanthan gum (commercially available), of 2% of the total weight of a cold transfer printing paste was placed in a mixer, and stirred for 2 hrs at a temperature of 70° C. and about 2500 r/min, and sodium L-pyrrolidonecarboxylate (PCA-Na) (commercially available) of 1% of the total weight of a cold transfer printing paste was added slowly with stirring, and mixed uniformly, to obtain a colloid pre-paste for use. In distilled water, a low-viscosity etherified starch of 28% of the total weight of a cold transfer printing paste was placed in a reactor, and heated with stirring at a low speed. After the temperature was raised to 85° C., heating was stopped, and the mixture was stirred for 2 hrs at a rotation speed of about 1400 r/min, to obtain a light gray transparent starch pre-paste. The colloid pre-paste and the starch pre-paste were mixed at room temperature, and distilled water was added to 100%, and the mixture was stirred uniformly, to obtain a cold transfer printing paste.
Embodiment 2 Preparation of Cold Transfer Printing Paste
Formula components are:
xanthan gum
0.5%,
sodium L-pyrrolidonecarboxylate
0.4%,
an etherified starch
45%, and
distilled water
added to 100%.
As for the preparation method, reference can be made to the flow chart of a process of formulating a cold transfer printing paste shown in FIG. 1 . Specifically, in distilled water, xanthan gum of 5% of the total weight of a cold transfer printing paste was placed in a mixer, and stirred for 2 hrs at a temperature of 70° C. and about 2700 r/min, and sodium L-pyrrolidonecarboxylate (PCA-Na), of 0.4% of the total weight of a cold transfer printing paste was added slowly with stirring, and mixed uniformly, to obtain a colloid pre-paste for use. In distilled water, a low-viscosity etherified starch (commercially available), of 45% of the total weight of a cold transfer printing paste was placed in a reactor, and heated with stirring at a low speed. After the temperature was raised to 85° C., heating was stopped, and the mixture was stirred for 2 hrs at a rotation speed of about 1400 r/min, to obtain a starch pre-paste, where the whole paste was light gray and transparent. The colloid pre-paste and the starch pre-paste were mixed at room temperature, and distilled water was added to 100%, and the mixture was stirred uniformly, to obtain a cold transfer printing paste.
Embodiment 3 Preparation of Cold Transfer Printing Paste
Formula components are:
guar gum
3.5%,
sodium L-pyrrolidonecarboxylate
3%,
an etherified starch
20%,
distilled water
added to 100%.
As for the preparation method, reference can be made to the flow chart of a process of formulating a cold transfer printing paste shown in FIG. 1 . Specifically, in distilled water, guar gum (commercially available), of 3.5% of the total weight of a cold transfer printing paste was placed in a mixer, and stirred for 2 hrs at a temperature of 70° C. and about 1400 r/min, sodium L-pyrrolidonecarboxylate (PCA-Na), of 3% of the total weight of a cold transfer printing paste was added slowly with stirring, and mixed uniformly, to obtain a colloid pre-paste for use. In distilled water, a low-viscosity etherified starch of 20% of the total weight of a cold transfer printing paste was placed in a reactor, and heated with stirring at a low speed. After the temperature was raised to 85° C., heating was stopped, and the mixture was stirred for 2 hrs at a rotation speed of about 1400 r/min, to obtain a starch pre-paste, where the whole paste was light gray and transparent. The colloid pre-paste and the starch pre-paste were mixed at room temperature, and distilled water was added to 100%, and the mixture was stirred uniformly, to obtain a cold transfer printing paste.
II Common Preparation Method of Printing Colorant
Herein, with a KN type active dye as an example, common preparation of a printing colorant of the present invention is described with a preferable implementation and an exemplary implementation.
The weight percentages of components of the printing colorant are as follows:
a cold transfer printing
24% to 26% (the cold transfer
paste
printing paste of Embodiment
1, 2 or 3),
an active dye
20% to 25%,
a defoarner
0.3% to 0.4%,
a flatting agent
0.3% to 0.5%,
a pH stabilizer
0.6% to 1.0%, and
deionized water
added to 100%.
A common formulation method of the printing colorant is as follows:
FIG. 2 shows a flow chart of a common process of formulating a printing colorant. Specifically, in deionized water, an active dye of 20% to 25% is pre-dissolved, and a solvent ethylene glycol monobutyl ether is added till the dye is completely dissolved. Next, to the solution, a cold transfer printing paste of 24% to 26%, a flatting agent of 0.3% to 0.5%, a defoamer of 0.3% to 0.4% and a pH stabilizer of 0.6% to 1.0% are added and stirring for 45 to 60 min at a stirring speed of 1200 to 1480 r/min. Then, ethylene glycol is added to the mixture to adjust the viscosity of the colorant to 1000 to 1300 centipoise at 25° C., to obtain a crude colorant. The resulting colorant is ground to a particle diameter in a ball mill for about 2 hrs, so that the ground colorant can pass through a 200-mesh sieve, and then the surface tension is adjusted to ≧40 dyne with diethylene glycol, to obtain the printing colorant. The active dye used in this implementation is a KN type active dye, and may also be an M type active dye; and the cold transfer printing paste may be the cold transfer printing paste of any one of Embodiments 1 to 3.
Embodiment 4 Preparation of Printing Colorant
A KN type active dye is used to formulate a colorant, and as for the formulation process, reference can be made to the flow chart of a process of formulating a printing colorant shown in FIG. 2 .
The KN type active dye printing colorant includes, by weight percentage:
an active dye, KN type active dye (commer-
24%,
cially available),
a cold transfer printing paste
25% (the cold transfer
printing paste of any one
of Embodiments 1 to 3),
a tributyl phosphate (commercially available),
0.3%,
defoamer
a polyether modified methyl alkyl polysiloxane
0.4%,
flatting agent (commercially available),
a pH stabilizer (a mixture of sodium dihydrogen
0.8%, and
phosphate and disodium hydrogen phosphate
at a weight ratio of 1:1),
deionized water
added to 100%.
As for the formulation method, reference can be made to the common formulation method of the printing colorant.
In this embodiment, the pastes of Embodiments 1 to 3 are respectively used to prepare a printing colorant, to obtain printing colorants marked as a printing colorant 41, a printing colorant 42 and a printing colorant 43.
Embodiment 5 Preparation of Printing Colorant
A Remazol type active dye is used to formulate a colorant, and as for the formulation process, reference can be made to the flow chart of a process of formulating a printing colorant shown in FIG. 2 .
The Remazol type active dye printing colorant includes, by weight percentage:
an active dye, Remazol type active dye
29.9%,
(Dystar Company),
a cold transfer printing paste
30% (the cold transfer
printing paste of any one
of Embodiments 1 to 3),
a polyester modified siloxane defoamer
0.3%,
(commercially available),
a polyether modified polydimethyl siloxane
0.3%,
(commercially available), flatting agent
a pH stabilizer (a mixture of sodium
0.5%, and
dihydrogen phosphate and disodium
hydrogen phosphate at a weight ratio of 1:1)
deionized water
added to 100%.
As for the formulation method, reference can be made to the common formulation method of the printing colorant.
In this embodiment, the pastes of Embodiments 1 to 3 are respectively used to prepare a printing colorant, to obtain printing colorants marked as a printing colorant 51, a printing colorant 52, and a printing colorant 53.
Embodiment 6 Preparation of Printing Colorant
A P type active dye is used to formulate a colorant, and as for the formulation process, reference can be made to the flow chart of a process of formulating a printing colorant shown in FIG. 2 .
The P type active dye printing colorant includes, by weight percentage:
a P type active dye (manufactured by Huntsman
16%,
International LLC.)
a cold transfer printing paste
22% (the cold transfer
printing paste of any one
of Embodiments 1 to 3),
a polyorganosiloxane defoamer (commercially
0.4%,
available),
a polyether modified methyl alkyl polysiloxane
0.4%,
flatting agent
a pH stabilizer (a mixture of sodium dihydrogen
1%, and
phosphate and disodium hydrogen phosphate
at a weight ratio of 1:1),
deionized water
added to 100%.
As for the formulation method, reference can be made to the common formulation method of the printing colorant.
In this embodiment, the pastes of Embodiments 1 to 3 are respectively used to prepare a printing colorant, to obtain printing colorants marked as a printing colorant 61, printing colorant 62, and a printing colorant 63.
III Tests of Performance of the Paste and the Printing Colorant of the Present Invention
Test samples
the paste of the present invention: the paste of Embodiments 1, 2, and 3; and
the printing colorant of the present invention: the printing colorants 41, 42, 43, 51, 52, 53, 61, 62, and 63.
Test methods
According to the method in Patent CN200510026661.2 “Production process of printing whole cotton transfer printing paper by gravure printing machine”, a transfer printing paper is produced by using the colorant, and transfer printing is performed by using Patent CN200620039111 “carpet tape transfer device of cold transfer printing machine”.
Indexes
1. Transfer rate: Transfer rate (%)=amount of the dye transferred and printed/oringial amount of the dye on the printing paper (%);
2. Color fixation rate: Color fixation rate (%)=amount of the dye bonded with the fabric fiber after color fixation/amount of the dye on the surface of the fabric before color fixation;
3. Color fastness: referring to GB/T 3920-1997 Textile Color Fastness Test Color Fastness to Rubbing;
4. Printing pattern fineness evaluation: For the same pattern, visual comparison is performed for evaluation.
Test results: The test results are listed in Table 1.
TABLE 1
Comparison table of the quality of printing products
using different colorants
Color
Transfer
Fixation
Color
Printing Pattern
colorant
Rate
Rate
Fastness
Fineness Evaluation
Colorant 41
96%
90%
88%
High fineness, no inflitration
Colorant 42
92%
88%
86%
High fineness, with pigment
residue
Colorant 43
90%
87%
85%
High fineness, with inflitration
(slight amount)
Colorant 51
90%
86%
85%
High fineness, no inflitration
Colorant 52
88%
84%
82%
Fineness, with white spots
Colorant 53
87%
84%
82%
Fineness, with pigment residue
Colorant 61
85%
83%
80%
Acceptable fineness, with
white spots
Colorant 62
82%
81%
80%
Low fineness, with pigment
residue
Colorant 63
82%
80%
80%
Acceptable fineness, with
pigment residue
Persons of ordinary skill in the art generally expect that the three parameters, namely, the transfer rate, the color fixation rate and the color fastness are respectively greater than 80%.
It can be seen from the results in Table 1 that the printing paste and the printing colorant of the present invention achieve good effect in one or more aspects of the transfer rate, the color fixation rate, the color fastness and the pattern fineness.
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The present invention relates to a cold transfer printing paste, a printing colorant and preparation methods thereof. Specifically, the present invention relates to: a cold transfer printing past, which contains polysaccharide, sodium L-pyrrolidonecarboxylate, an etherified starch and water; a printing colorant, which contains the paste of the present invention, an active dye, a defoamer, a flatting agent, a pH stabilizing agent and water; and preparation methods of the paste and the printing colorant. The cold transfer printing paste of the present invention and a printing colorant containing the paste are applicable in a cold transfer printing process, and have stable physical properties, thereby preventing decrease of the viscosity in use.
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BACKGROUND OF THE INVENTION
The invention relates in general to a hybrid vehicle drive system having a primary power source, such as a conventional internal combustion engine, and another power source, such as a source of high pressure pneumatic or hydraulic fluid. More particularly the invention pertains to braking the wheels of a hydraulic hybrid vehicle.
Hydraulic Power Assist (HPA) is a type of hydraulic hybrid vehicle, in which energy from regenerative braking or from an engine is stored in a hydro-pneumatic accumulator, and the conversion between mechanical power and hydraulic power is achieved through high pressure pump/motor having a variable volumetric displacement. In an HPA system, using stored energy from regenerative braking to help accelerate the vehicle reduces the burden on the engine and reduces fuel use.
Because of the high power density available with such hydraulic systems, it is possible to recover efficiently a significant portion of braking energy with an HPA system comprised of a single pump/motor and storage accumulators. With a 7000 lb. vehicle and a pump/motor whose maximum displacement is 150 cc., an HPA system can recover 72 percent of the available braking energy in the Environmental Protection Agency (EPA) city cycle. The pump/motor operates for long periods at higher displacements and with a relatively high cycle average efficiency of 88 percent. With a return of 56 percent of the braking energy to the drive wheels (72 percent recovered in braking, and 88 percent transfer efficiency in both pumping and motoring), it is possible to recover 56 percent of the vehicle kinetic energy (or 75 percent of the velocity) while accelerating, neglecting road load friction. In the EPA city cycle it was possible to fill the hydraulic system when braking from 30 mph and then moderately accelerate again to about 22 mph using only stored energy from the HPA system.
SUMMARY OF THE INVENTION
Using regenerative braking energy for vehicle acceleration can provide a significant fuel economy benefit without the complications of engine start-stop capabilities or cruise load leveling. Since HPA can provide this fuel economy benefit without significant changes to the conventional powertrain, it is possible to achieve the fuel economy benefit without adversely affecting vehicle performance.
It is also possible to significantly augment vehicle performance over the engine-only powertrain, especially in a heavier vehicle. Fuel economy and performance benefits can be optimized for a given application.
A system for braking the wheels of a hydraulic hybrid vehicle includes a brake pedal having a range of pedal displacement including a deadband displacement range, an accumulator containing fluid at relatively high pressure, a reservoir containing fluid at lower pressure, a pump/motor having variable volumetric displacement connected to the accumulator and reservoir, and driveably connected to the wheels; a system responsive to brake pedal displacement in the deadband range for placing the pump/motor in a pump state wherein the pump/motor is driven by the wheels and pumps fluid from the reservoir to the accumulator; and a control valve for changing the volumetric displacement of the pump/motor in response to displacement of the brake pedal.
The invention relates to a method for braking the wheels of a vehicle that includes an accumulator containing fluid at relatively high pressure, a reservoir containing fluid at lower pressure, a pump/motor having variable volumetric displacement connected to the accumulator and reservoir are driveably connected to the wheels, and a brake pedal having a range of pedal displacement. A desired vehicle is determined on the basis of the pedal displacement, and a magnitude of braking force to decelerate the vehicle at the desired deceleration is determined. A wheel torque corresponding to the required braking force, a net wheel torque to stop the vehicle at the desired deceleration from a current vehicle speed, and a torque magnitude to be applied to the pump/motor by the wheels based on the net wheel torque are determined. Then the pump displacement corresponding to the magnitude of torque to be applied to the pump/motor by the wheels to produce the desired deceleration rate is determined. Finally, the magnitude of pump displacement is changed to the pump displacement corresponding to the torque magnitude to be applied by the wheels to the pump/motor.
Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a powertrain for a hydraulic hybrid motors vehicle that operates in a brake regenerative mode and power assist mode.
FIG. 2 is a schematic diagram of a brake pedal for use in controlling the brake regeneration mode of the powertrain of FIG. 1 .
FIG. 3 is a hydraulic circuit diagram showing the pump/motor, accumulator, control valves and hydraulic lines connecting them.
FIG. 4 is diagram of logic for controlling the brake regeneration mode in a deadband range of brake pedal position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 a hydraulic hybrid powertrain 10 for driving the rear wheels 12 , 14 of a motor vehicle. A power source 16 , such as an internal combustion engine, is driveably connected to a transmission 18 , preferably an automatic transmission producing multiple ratios of the speed of the engine and the speed of an output shaft 20 . Suitable alternative transmissions include those that are manually operated, and those that produce continuously variable speed ratios or infinitely variable speed ratios, having chain drive, belt drive or traction drive mechanisms. The powertrain can be adapted to drive the front wheels 14 instead, and may include a transfer case for operating in all-wheel drive or four-wheel drive modes.
A pump/motor 26 having variable displacement is driveably connected to the transmission output shaft 20 and to a driveshaft 22 . When torque is transmitted in a positive torque direction, from the engine to the wheels, output shaft 20 drives the pump/motor 26 ; when torque is transmitted from the wheels to the engine, the negative torque direction, driveshaft 22 drives the pump/motor 26 .
During the power assist mode, while the vehicle is accelerating, pressure in accumulator 40 is released, high pressure fluid drives the pump/motor 26 , and the wheels 12 are driven in rotation by the pump/motor, which operates then as a fluid motor. The motor 26 drives the wheels 12 through the driveshaft 22 , differential 23 and the axles 30 , 32 .
During the brake regeneration mode, while the vehicle is decelerating while being braked, vehicle kinetic energy or momentum is initially reduced by causing the wheels 12 to drive the pump/motor 26 through the axles 30 , 32 and driveshaft 22 . The pump/motor 26 operates during the brake regeneration mode as a pump across a pressure differential between the pump inlet 112 , which communicates with reservoir 36 , and the pump outlet 90 , which communicates with accumulator 40 . The pump/motor 26 pumps fluid from reservoir 36 to the accumulator 40 . Fluid entering the accumulator 40 compresses nitrogen contained in a bladder located in the accumulator 40 , and the accumulator is pressurized.
Referring now to FIG. 2 , in a conventional vehicle, when the foot brake pedal 50 is applied, the vehicle decelerates due to friction braking, i.e., frictional contact of brake pads or brake shoes on wheel brake rotors or drums. The kinetic energy of the vehicle is converted by this frictional contact to heat, which is dissipated. In a deadband parallel regenerative braking system, a space 52 is located between connecting rods, 54 , 56 , which connect a brake master cylinder 58 and the foot brake pedal 50 . The space 52 causes the brake pedal to move from the rest position shown in FIG. 2 through a first portion of its full displacement before hydraulic brake pressure is generated in the master cylinder due to movement of the piston 60 within the master cylinder 58 . This delays the application of the wheel friction brakes as the pedal is being displaced. The range of brake pedal displacement in which no friction braking occurs, called the “deadband” region, is preferably about 30 percent of the full range brake pedal displacement beginning when the brake pedal is at rest and not displaced.
A tension spring 68 , fastened to a brake lever 64 between the fulcrum 66 and the pedal 50 , provides a force sensed by the vehicle operator and resisting brake pedal displacement in the deadband range. The force of spring 68 , produced when depressing the brake pedal 50 , compensates for the absence of a hydraulic pressure force opposing pedal displacement and piston movement in the master cylinder while the pedal is in the deadband range. A brake pedal position transducer 70 produces an electronic signal carried on line 72 to an electronic controller 74 , the signal representing brake pedal position. Controller 74 operates under control of a microprocessor, which executes programmed logic. A power brake canister 76 contains a piston 78 , which is actuated by engine vacuum to increase the force applied to connecting rod 54 by depressing the brake pedal 50 .
Pressure in the hydraulic brake system 80 , which actuates friction brakes 82 , changes when pressure in the master cylinder 58 changes due to movement of piston 60 as the brake pedal 50 is displaced. When the brake pedal 50 is depressed beyond the deadband range sufficiently to close the space 52 , brake system pressure forces the brake pads into frictional contact with the brake disc 84 , to which a wheel 12 is fixed.
In addition to the friction brakes, the vehicle is braked also by a regenerative brake system. While the brake pedal 50 is depressed, the operating states of hydraulic pump/motor 26 are changed between a pump state and motor state in response to command signals produced by controller 74 and supplied to a solenoid 86 , which operates a mode valve 88 . When valve 88 is in the position shown in FIG. 3 , the pump/motor 26 is connected hydraulically to the high pressure accumulator 40 , and the system operates in the motor mode, in which the wheels 12 , 14 are driven by the motor 26 being actuated by high pressure fluid from accumulator 40 . When the state of valve 88 is changed by solenoid 86 in response to a command signal from controller 74 , the pump/motor 26 is connected hydraulically to the low pressure reservoir 36 , and the system operates in the pump mode, in which the wheels 12 , 14 drive pump 26 , which pumps fluid from reservoir 36 to accumulator 40 .
A swashplate control valve or proportional valve 96 changes the variable displacement of the pump/motor 26 in response to commands issued by controller 74 . Pump displacement is directly related to the torque necessary to rotate the pump rotor at a given hydraulic pressure. When the brake pedal 50 is in the deadband range, the system operates in the pump mode, and vehicle braking is entirely accomplished by the pump 26 . If the brake pedal is displaced past the deadband range, vehicle braking is accomplished by a combination by regenerative braking and friction braking in the correct proportion to achieve the vehicle deceleration rate desired by the vehicle operator.
Solenoid 98 changes the state of valve 96 among three positions or states, a center position where the inlet and outlet of valve 96 are mutually disconnected, a left-hand position where displacement of the pump/motor 26 decreases, and a right-hand position where displacement of the pump/motor 26 increases. An isolation valve 128 , controlled by solenoid 130 in response to command signals from controller 74 , alternately opens and closes a connection between accumulator 40 and an inlet of valve 96 . The reservoir 36 is connected to an inlet of valve 96 through a check valve 99 . When valve 96 is in the left-hand state, the state shown in FIG. 3 , accumulator 40 is connected through valves 128 and 96 to the pump/motor 26 . Pressure from accumulator 40 changes the angular position of a swashplate in the pump/motor 26 tending to increase the swashplate angle and decrease the volume of fluid that passes through the pump/motor 26 during each revolution, its volumetric displacement. When valve 96 moves to the right-hand state illustrated in FIG. 3 , accumulator 40 is connected through valves 96 and 128 to change the angular position of the swashplate, tending to decrease the swashplate angle and increase volumetric displacement of the pump/motor 26 .
Referring now to FIG. 4 , after the vehicle operator depresses the brake pedal, the extent to which the brake pedal is depressed 150 , called “brake pedal position,” is used to determine the current desired vehicle deceleration rate 152 . Brake system hydraulic pressure 154 at the wheel brakes is used with the brake pedal position 150 to determine the corresponding vehicle deceleration rate due to applying the friction brakes 156 . Parasitic drag on the vehicle 158 due to tire friction and air friction, and the effects of engine braking are used to determine vehicle deceleration due to these factors. The vehicle deceleration rates 150 , 156 , 158 are added algebraically at summing junction 160 to produce a net vehicle deceleration rate 162 .
At 164 , the vehicle mass is multiplied by the net vehicle deceleration rate 162 to produce the magnitude of force, which if applied to the vehicle, would produce the net vehicle deceleration rate.
That force is converted at 166 to an equivalent wheel torque using the tire size and a nominal coefficient of friction between the tires and the road surface. At 170 , the wheel torque required to maintain the current vehicle speed is calculated. At summing junction 172 , the magnitude of the difference between torques 166 and 170 is calculated to determine the change in wheel torque 174 necessary to stop the vehicle from the current speed at the desired deceleration rate 152 .
At 176 , that differential torque 174 is divided by the axle ratio to determine the magnitude of torque 178 that must be deducted from the torque transmitted by the driveshaft 22 to the pump motor 26 in order to produce the desired vehicle deceleration rate 152 . Then at 180 , the pump displacement corresponding to torque 178 is calculated. The controller 74 produces a command signal that is transmitted to solenoid 98 of the proportional valve 96 in order to change the angular position of the swashplate and to change the displacement of the pump/motor 26 to the calculated pump displacement calculated at 180 .
In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
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A system for braking the wheels of a hydraulic hybrid vehicle includes a brake pedal having a range of pedal displacement including a deadband displacement range, an accumulator containing fluid at relatively high pressure, a reservoir containing fluid at lower pressure, a pump/motor having variable volumetric displacement connected to the accumulator and reservoir, and driveably connected to the wheels; a system responsive to brake pedal displacement in the deadband range for placing the pump/motor in a pump state wherein the pump/motor is driven by the wheels and pumps fluid from the reservoir to the accumulator; and a control valve for changing the volumetric displacement of the pump/motor in response to displacement of the brake pedal.
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This application is a divisional application of U.S. patent application Ser. No. 09/433,251, filed Nov. 4, 1999 since patented as U.S. Pat. No. 6,261,030, which claims the benefit of U.S. Provisional Application No. 60/107,671 filed Nov. 5, 1998.
FIELD OF THE INVENTION
The present invention relates to improvements in desiccant feeder systems and apparatus.
BACKGROUND OF THE INVENTION
The prior art patents listed below show bottle unscrambling systems and apparatus. However, these patent do not teach or suggest the desiccant feeding system and apparatus of the present invention.
Omega Design Corp. U.S. Pat. No. 5,421,447
HIGH RATE TRANSFER WHEEL FOR ORIENTING
UNSCRAMBLED CONTAINERS
Issued: Jun. 6, 1995
and
Omega Design Corp. U.S. Pat. No. 4,655,338
BOTTLE UNSCRAMBLER
Issued: Apr. 7, 1987
SUMMARY OF THE INVENTION
The canister desiccant feeder of the present invention has seven areas to be monitored for optimum machine performance. They are reservoir hopper, pre-orienter, air transfer device, desiccant shuttle system, container handling system, verification system, rejection station and discharge conveyor.
The hopper supplies desiccant by gravity feed through a “stopper” valve at the bottom of the reservoir. The stopper valve is actuated by a connecting rod and lever attached to an air cylinder outboard of the reservoir. The stopper is cycled open and closed when the pre-orienter requires desiccants. The cycle time and the movement of the stopper should not require adjustments during normal operation.
The pre-orienter begins the orienting process by forming a single column of desiccants and transferring the column to the air transfer device. A sensor called the pre-orienter sensor controls the quantity of desiccants in the pre-orienter. This sensor signals the stopper valve to open and close, hence delivering desiccants to the pre-orienter. The level of desiccants directly affects the overall operating efficiency of the pre-orienter.
Sorter discs are used to form a groove or trough in which the desiccants are columnized. Sorter discs are exchanged at changeovers to form different size grooves for different size/shape desiccants. Air jets are used to help position the desiccants properly in the sorter disc's groove.
The air transfer device for the present invention transports the oriented desiccants from the pre-orienter to the shuttle. The air transfer device utilizes compressed air to transfer the desiccants. Upon the exit from the pre-orienter a reducer is coupled to an air amplifier, which is connected to a discharge tube and the desiccant transfer tubing. Slots milled into the tubing regulate the fill height of the desiccants to a determined height and once the slots are blocked then the back pressure in the tubing will not allow the transfer of any more desiccants. A sensor is mounted to confirm the presence of desiccants within the tube. If the eye acknowledges absence of desiccants, then the container handling system is stopped.
The desiccant shuttle system consists of a main housing (top and bottom block), a linear electronic solenoid, a spring and a desiccant transfer block. The desiccants are supplied to the shuttle by the aforementioned transfer device and then are available for dispensing. The shuttle is in a non-active (retracted) state and the proper quantity of desiccants are stopped by a ridge on the bottom block and allowed to stack. The desiccants will remain in this configuration until activation. The activation is provided through a gate eye sensor, which signals the linear solenoid to activate. Desiccants are then moved within the transfer block to a position where the desiccants can exit the transfer block into the bottle below. Exit from the transfer block is assisted by an air nozzle to achieve higher speed. The transfer block is maintained in its extended position for a determined period of time. Next, the linear solenoid is deactivated and a spring returns the transfer block to its original position.
Desiccants are dispensed into the bottles at a predetermined speed which is dependent upon the neck of the bottle. In accordance with the verification system of the present invention, the eye verifies if a desiccant has been inserted into the bottle. The eye is mounted under the bottle in the container handling system and senses through the bottle for the desiccant. The system also includes a leading edge eye sensor and a trailing edge eye sensor. The leading edge eye determines when a bottle is entering the verification area and the trailing edge eye determines when it is leaving the area. If a desiccant is not detected, then the bottle is rejected at the rejection station. The rejection station rejects the bottle via an air jet into a bin.
In accordance with the discharge conveyor of the present invention, the discharge conveyor's tabletop chain speed should be adjusted to provide a smooth transfer of containers through the system. A sensor called the backlog sensor monitors the conveyor discharge conditions at the edge of the canister desiccant feeder. Should the conveyor backlog or overload, the backlog sensor will signal the entire canister desiccant feeder to pause. Once the blockage has cleared, the machine will automatically restart. Minor adjustments to the timer settings of the sensor may be required to compensate for actual in-plant operations, conveyor velocities and container sizes and shapes.
The system of the present invention has many features. They include the fact that the system may be mounted on an adjustable free-standing mobile frame which can be easily moved into and over existing conveyor systems. The system is fully automatic and provides on demand operation with discharge backlog detection. The system is adaptable to a ten gallon unit mounted floor-level hopper with vertical elevator to minimize floor space requirements. The system is provided with a desiccant drop verification and is fully guarded with interlocks. The system does not require changing the parts for different sized bottles or containers and provides positive container control through variable speed side belts with shaft encoder to track container speeds. The system and apparatus of the present invention also has a container reject for missing desiccant with reject verification.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention and various features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic side elevational view showing a system for delivering a continuous stream of desiccant canisters to a shuttle system, the shuttle discharging single or multiple desiccant canisters into individual containers carried at high speed on a bottle unscrambling turret.
FIG. 2 is a schematic plan view of FIG. 1 showing the desiccant reservoir and pre-orienter, air transfer device, desiccant transfer tubing, shuttle assembly, bottle unscrambling turret, conveyor, rejection station and sensor locations.
FIG. 2A is a side elevational view partially in section showing a typical bottle having a desiccant canister contained therein.
FIG. 3 is an enlarged fragmentary sectional side elevational view taken on the line 3 , 3 of FIG. 2 showing details of the air transfer device and a portion of the pre-orienter.
FIG. 4 is an enlarged fragmentary side elevational view of the detail contained within the dot and dash line shown in FIG. 3 and designated in FIG. 4 .
FIG. 5 is a fragmentary side elevational sectional view taken on the line 5 , 5 of FIG. 2 showing details of the shuttle assembly with its shuttle block in the forward or desiccant discharge position.
FIG. 6 is a fragmentary side elevational view similar to FIG. 5 showing the shuttle block in the retracted or desiccant loading position.
FIG. 7 is an isometric view of the shuttle original slide-design.
FIG. 8 is a sectional plan view taken on the line 8 , 8 of FIG. 5 showing additional details of the shuttle assembly.
FIG. 9 is a schematic side elevational sectional view taken on the line 9 , 9 of FIG. 2 showing how the bottles carried in the pocket assemblies of the bottle unscrambler have their bottom faces all raised to a common plane by means of a ramp prior to passing over a sensor so that the presence of a desiccant canister in each bottle may be determined.
FIG. 10 is a schematic fragmentary side elevational view showing a conveyor modification wherein a portion is broken away and in section to show certain details of construction.
FIG. 11 is a plan view of FIG. 10 .
FIG. 12 a is a perspective view of a shuttle modification in accordance with the present invention.
FIG. 12 b is a top plan view of the modified shuttle slide.
FIG. 13 a is a perspective view of a modified shuttle bottom block.
FIG. 13 b is a top plan view of the shuttle block.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIGS. 1 and 2 thereof, there is shown a system and apparatus for delivering desiccant canisters (C) and depositing predetermined preselected canisters in a container or bottle (B) in a continuous assembly line fashion. The desiccant feeding and loading system is shown in association with a bottle unscrambler, generally of the type shown in U.S. Pat. No. 4,655,338 entitled, BOTTLE UNSCRAMBLER, which issued Apr. 7, 1987 and is owned by Omega Design Corp., assignee of the present application. The bottle orienting system comprises a rotating turret ( 10 ) having a plurality of pocket assemblies ( 12 ) disposed at equi-spaced locations circumferentially around the turret ( 10 ). The bottles (B) are fed into a feeding station (S f ) in either a top down or top up condition and as they are rotated by the turret ( 10 ), they are oriented to a top up position at a desiccant feeding and loading station (S d ) where desiccant canisters (C) are discharged, for example, one to a bottle (B) and then delivered to a discharge conveyor (C d ).
The basic elements of the desiccant feeder system include a reservoir ( 30 ) wherein desiccant canisters (C) are fed in random fashion and are delivered to a pre-orienter ( 32 ) which orients the canisters (C) single file, end to end, for delivery to an infeed tube ( 34 ) of an air transfer device ( 36 ). The air transfer device ( 36 ) releases a predetermined amount of compressed air at high velocity through an internal ring-shape nozzle to drive the desiccant canisters (C) through desiccant transfer tubing (T d )connecting the air transfer device ( 36 ) to a desiccant shuttle assembly ( 50 ) at the desiccant feeding and loading station (S d ). As explained in more detail hereafter, the air released through the nozzle creates a strong vacuum drawing additional ambient air through the infeed tube ( 34 ) and pulling additional surrounding air through the rear of the air transfer device while pushing the ambient air in front. This creates a very efficient delivery system at relatively low air pressures, in the order of 10 psi.
The desiccant delivery station (S d ), as best illustrated in FIGS. 1 and 5 includes a shuttle assembly ( 50 ), which in the present instance, is mounted on an upstanding support frame ( 53 ) so that it may be selectively adjusted in a vertical direction for ease of aligning the shuttle assembly ( 50 ) with respect to the bottle unscrambler turret ( 10 ). The shuttle assembly ( 50 ) is of relatively simplified construction and comprises a top block ( 52 ) and a bottom block ( 54 ) which are held in assembled relation by a draw latch ( 56 ). A shuttle slide ( 60 ) having a discharge opening ( 62 ) is mounted for sliding movement in the shuttle bottom block ( 54 ) between a first limit or rest position (FIG. 6) blocking flow of desiccant canisters (C) through the discharge opening ( 63 ) in the shuttle bottom block ( 54 ). In this position, the discharge opening ( 62 ) is aligned with the stack of desiccants in the accumulator tube ( 66 ). A second discharge limit position (FIG. 5) wherein the discharge opening ( 62 ) is aligned with the opening in the bottom block ( 63 ), thus permitting discharge of a single canister (C) to a bottle (B). The shuttle slide ( 60 ) is cycled between the limit positions by a spring biased solenoid ( 67 ) having a rod ( 68 ) connected to the shuttle slide ( 60 ) and a conventional extension spring ( 70 ) normally biasing the shuttle slide ( 60 ) to its second blocking limit position (FIG. 6 ). When the solenoid is energized, it moves the shuttle slide ( 60 ) to the discharge limit position (FIG. 5 ). The shuttle top block ( 52 ) mounts a fitting ( 72 ) connected through a line ( 74 ) to the pressurized air supply to direct air through an internal channel ( 76 ) and propel desiccant canisters (C) directly into the bottle (B) in the manner shown in FIG. 5 .
The shuttle slide ( 60 ) has an entrance ramp ( 61 ) cut below the level of the top of the discharge opening ( 62 ) so that as the shuttle slide ( 60 ) is moved to its first limit position, the desiccant canisters (C) in the stack rest on the ramp and ensure the release of a predetermined number of canisters (C) in the manner shown and described.
Conventional sensors operatively connected to various components of the system are provided for synchronizing the feed and delivery of the desiccants to the open containers as they are moved at a constant speed through the desiccant discharge and feeding station (S d ). To this end, a so-called gate sensor ( 80 ) is disposed in the path of the pocket assemblies and is operatively connected to the shuttle slide ( 60 ), solenoid ( 67 ) so that if it senses a pocket assembly coming into the station as having a bottle (B), then it activates the solenoid ( 67 ) to cycle the shuttle slide ( 60 ) to feed a desiccant canister (C) to the bottle (B). If the pocket assembly entering the station is not loaded with a bottle (B), the gate eye sensor ( 80 ) does not activate the solenoid ( 67 ).
Downstream of the desiccant loading and feeding station (S d ) is a verification sensor ( 90 ) which is mounted in an upwardly inclined ramp ( 92 ). The leading edge sensor ( 94 ) and trailing edge sensor ( 96 ) in cooperation with the verification sensor ( 90 ) are operatively connected to a reject mechanism ( 100 ) so that bottles (B) passing through the station without a desiccant canister (C) are discharged from the conveyor at the rejection station (S r ).
In some instances, it is desired to feed two desiccant canisters (C) to each bottle (B). In this instance, the system can be easily modified to accommodate feeding two at a time. The shuttle block bottom assembly is simply removed and replaced with one wherein the shuttle slide ( 60 ) has a discharge opening twice the height of a desiccant canister. To do this, the draw latch and hinge are simply disengaged. Then, the new bottom block assembly can be mounted and in all other respects operates the same as in the manner described above.
Considering now the air transfer assembly, the construction and details thereof are best shown in FIGS. 3 and 4. As shown therein, air transfer assembly comprises an air amplifier infeed tube ( 120 ) having a central bore ( 123 ) of a diameter (D) slightly larger than the diameter (D 1 ) of the desiccant canisters (C) and has an enlarged inner end ( 121 ) terminating at a circumferentially extending frusto-conical face ( 122 ) which is stepped as at 124 at it inner terminal end to define a circumferentially extending air inlet chamber ( 126 ). The assembly further includes an elongated tubular air amplifier throat member ( 130 ) having a frusto-conical face ( 132 ) complementing and confronting the frusto-conical face ( 122 ) of the air amplifier infeed tube. The air amplifier throat member ( 130 ) and air amplifier infeed tube ( 120 ) are held in the abutting relationship shown in FIG. 3 by a nozzle reducer ( 140 ). The assembly further includes an amplifier discharge tube ( 142 ) having an outwardly diverging flared inner face ( 142 a ) adjacent its inner end which confronts the air amplifier infeed tube ( 120 ) and which serves as a pilot section directing the desiccant canisters (C) to the discharge tube in the manner shown in FIG. 3 . An intermediate sleeve ( 146 ) is mounted on the inner end of the amplifier discharge tube ( 142 ) and has external threads which mate with threads on the air amplifier throat ( 130 ).
A nut ( 150 ) is used to secure the parts in place in the manner shown in FIG. 3 . The sleeve ( 146 ) has a annular undercut at its inner end defining an air chamber ( 152 ). A fitting ( 153 ) connects the air chamber ( 152 ) to a pressurized air supply (S a ). The flexible tube (T d ) as illustrated is connected at its inner end to the air amplifier discharge tube ( 142 ). As shown by the arrows, pressurized air from a source enters the fitting and flows into the annular chamber ( 152 ) and from there the air is directed inwardly through the annular chamber ( 124 ) to the bore of the amplifier discharge tube. This arrangement creates a vacuum, thereby pulling additional air from the ambient environment through the amplifier infeed tube ( 34 ) as shown by the arrows designated X.
Consider briefly, the operation of the system and apparatus as described. Desiccant canisters (C) flow from the reservoir ( 30 ) to the pre-orienter ( 32 ) and into the amplifier infeed tube ( 34 ) where they arrive in an end to end configuration. This tube as shown has a diameter slightly larger than the diameter of the canisters (C) so that they accumulate in the air infeed tube in an end to end array. Pressurized air drives the canisters (C) through the desiccant transfer tubing (T d ) and deliver the canisters (C) to the accumulator tube ( 66 ) at the desiccant loading station (S d ). An opening is provided in the tubing and accumulation tube at points 154 and 156 (as shown in FIG. 5 ). The transfer assembly will continue to automatically feed desiccant canisters (C) through the system until the supply of desiccant canisters in the accumulator tube ( 66 ) reaches the upper limit at 156 . At such point, back pressure within the transfer tubing (T d ) will prevent the transfer of desiccants. When the level of desiccant canister (C) falls below the lower limit ( 154 ), the bottle handling machine is stopped. If this condition lasts longer than the predetermined time, an alarm is triggered. The tubing is preferably of a fluorinated ethylene propylene (FEP) which is available under the trade name Chemfluor.
There is shown in FIGS. 10 and 11 a conveyor modification where it may be desired to locate the desiccant feeding and loading system of the present invention along the path of a conveyor rather than in association with the bottle unscrambler as described above. In this instance, the downflex conveyor section shown in FIGS. 10 and 11 is simply placed in the location desired for sensing bottles (B) and the desiccant loading station is appropriately positioned upstream of the downflex conveyor section. As illustrated, the conveyor belt ( 159 ) is diverted downwardly by a suitable modification and three sensors ( 160 ) are located across the width of the conveyor for sensing whether bottles (B) moving through this section of the conveyor are filled with the appropriate desiccant canister. The drive system for moving bottles (B) through the sensor station includes a series of rollers ( 158 ) and belts ( 159 ) and a suitable drive motor ( 164 ) for advancing the bottles (B) moving on the conveyor in the direction indicated through the sensing station.
It is shown in FIGS. 12 a - 13 b , inclusive, a modified form of shuttle assembly in accordance with the present invention which is generally similar in construction of the arrangement to that described previously except the slide is generally rectangular rather than rounded at its front and rear end. Accordingly, similar reference numerals have been assigned with the subscript “A”.
It has been found that this form of the shuttle assembly is easier and more economical to manufacture.
Even though particular embodiments of the present invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims.
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A desiccant feeder system comprising, a reservoir for desiccant canisters, means for delivering the canisters through a transfer tube to at a loading station, means for presenting the open end of containers one at a time at the loading station, means for circulating air at high velocity through the tubing including an adjustable internal ring-shaped nozzle to deliver desiccant canisters from the reservoir to the loading station, and a shuttle selectively actuatable to discharge at least one desiccant cannister to the containers at the loading station.
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BACKGROUND OF THE INVENTION
The invention relates to electrochemical generated gases and more specifically to a miniature, battery-like device for generating gases or as a power source or battery.
The use of electrochemically generated gases in fluid delivery is well known. Oxygen-driven fluid delivery, with oxygen being extracted from the air, has been described by Maget in the various U.S. Pat. Nos.: 4,687,423, 4,886,514, 4,902,278, 5,928,194, 5,938,640 and 6,383,165. Hydrogen-driven fluid delivery is exemplified by the Disetronic Infuser, a disposable syringe pump, which uses a galvanic cell as a hydrogen source.
In many applications, the rate of fluid delivery is of the order of a few microliters/hour over long periods of time, such as months. In U.S. Pat. No. 6,383,165, Maget describes such a delivery system which has been shown to operate at a constant delivery rate for about 4 months.
Many of these commercial applications are price-sensitive; such is the case of the long term release of pheromones in forestry and agriculture or the delivery of fragrances in the home environment. Therefore there is a need for economical, long-life, disposable gas generators.
In U.S. Pat. No. 6,387,228, Maget describes the electrochemical generation of carbon dioxide (CO2) and hydrogen (H2), based on the decomposition of organic acids, such as formic or oxalic acid. In the current invention, the inventors describe an extremely simple means to assemble and operate a miniature electrochemical gas generator, based on the decomposition of organic acids as described in '228, which meets the criteria for economy and longevity.
Such a generator is particularly well suited for the delivery of small quantities of liquids, such as pheromones, fragrances, insecticides, pesticides , or in general chemical agents, at extremely low flow rates.
OBJECTS OF THE INVENTION
It is the primary objective of this invention to provide for a simple, practical, economical gas generator which can be controllably operated for long time periods.
It is another object of this invention to show that the assembly of the electrochemical gas generator is extremely simple and does not require unusual skills, tools or equipment.
It is a further object of this invention to show that only minor modifications of the generator are required to achieve the desired longevity.
It is also an object of this invention to provide for a structure suitable as a battery using liquid fuels and air as an oxidant.
SUMMARY OF THE INVENTION
A miniature, battery-like device is described for the generation of gases or as a power source or battery. The generation of carbon dioxide and hydrogen by electrochemical decomposition of an aqueous oxalic acid solution is detailed. One of the electrodes of the internally located electrochemical cell is in intimate contact with the cathode cap of the device, while the other electrode is under compression from an internal spring of variable length which is in electrical contact with the anode cap. The low-cost device is easy to fill and assemble. It can be used for the controlled release of small quantities of fluid, delivered at low flow rates for long periods of time, such as pheromones, fragrances, insecticides, pesticides. It can also be used as power source using liquid fuels such as methanol and ambient air as a source of oxygen.
In the first embodiment, the electrochemical gas generator would be connected to a battery and current control circuit such as illustrated in FIG. 3 of the '228 U.S. patent. The gas generator would also be placed in a container containing liquid to be distributed. This container would have a liquid release port and the pressure of the gases released from the gas generator would periodically force small drops of the liquid out through the release port.
The second embodiment would function in a similar manner, but would release the hydrogen gases out of its anode cap.
The third embodiment, structurally identical to the second embodiment, would allow the H2 gas to react with oxygen (from air) to produce water. Whenever a methanol solution is used in the gas generator, the generator becomes energy-independent and operates simultaneously as a power source and as a CO2 generator.
In the fourth embodiment the electrochemical reaction does not produce CO2 and therefore obviates the need for an anode exit port, while air is allowed to access the cathode exit port, thereby creating a power generating fuel cell.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic exploded front perspective view of the electrochemical gas generator;
FIG. 2 is a schematic front perspective view illustrating the internal assembly of the electrochemical gas generator;
FIG. 3 is a schematic front perspective view of the assembled electrochemical gas generator;
FIG. 4 is a schematic exploded front perspective view of a first alternate embodiment of the electrochemical generator designed as a gas source for the separate release of CO 2 and H 2 or as a power source releasing CO 2 ;
FIG. 5 presents the experimental results of the relationship between current and voltage of the generator while operating at low currents;
FIG. 6 shows the pressure generated by the same generator under current control at three different currents;
FIG. 7 shows the stability of the generator voltage operating without current controller;
FIG. 8 is a schematic exploded front perspective view of the first alternative embodiment including an external battery used to operate the gas generator; and
FIG. 9 is a schematic exploded front perspective view of a second alternative embodiment that functions as a miniature fuel cell which employs a fuel which does not generate gaseous by-products and the oxygen from air as an oxidant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment consists of a container 1 enclosed by top and bottom caps 2 A and 2 B. Within container 1 is located spring 3 which is under compression and retained by caps 2 A and 2 B. One cap, 2 B holds electrochemical cell 4 . The other cap 2 A holds gas permeable membrane 7 , a seal 6 and a retaining ring 5 . Cap 2 A is only distinguished from cap 2 B in that it has a gas release port 8 . Oxalic acid 12 is shown in container 1 .
Container 1 is a plastic tube, made from a polyolefin (polypropylene or polyethylene). As a matter of illustration the plastic tube has a diameter of 10 mm. Its length is variable according to the expected longevity of the gas generator. Caps 2 A and 2 B are made of stainless steel, the gas port in cap 2 A has a diameter of about 0.5 mm. Electrochemical cell 4 consists of an ionomer capable of transporting hydrogen ions and of two electrodes. The ionomer can be Nafion, a registered trademark of DuPont Corp. The electrodes are noble metal blacks or activated carbons, as used in fuel cells. The electrochemical cell is surrounded by the oxalic acid solution, and therefore does not require seals or a specific geometry, and the generator's terminals can be either connected to the positive or negative terminals of the battery. For example, the cell could be located away from cap 2 A, provided that electric contact exists between the electrochemical cell anode and cap 2 A, as would be provided by another contact spring. Retainer ring 5 is made of stainless steel. Seal 6 is an elastomer, such as a nitrile rubber. Membrane 7 is permeable to the released gases, as available from W. L. Gore Corporation.
The purposes of these components are as follows:
One of the electrode of cell 4 is in intimate contact with cap 2 B. In this instance it forms the cathode of the electrochemical generator. Membrane 7 is permeable to gases, but not to liquid; therefore acting as a barrier to prevent fluid loss from the container. Seal 6 is provided for the purpose of preventing liquid to seep around membrane 7 . Retainer ring 5 is used to compress seal 6 and membrane 7 against cap 2 A, while also establishing electrical contact between spring 3 and cap 2 A. In this instance spring 3 establishes contact between one electrode of cell 4 and cap 2 A, thereby becoming the anode of the generator. Finally, the oxalic acid necessary to produce the gas is located, as a solution within container 1 .
Once assembled, as illustrated in FIG. 2 , the spring applies pressure against the electrochemical cell, insuring contact with the cathode cap, while also establishing contact with electrochemical cell anode and anode cap 2 A.
FIG. 3 shows the completed assembled generator. As an illustration it has a diameter D1 of 10 mm and a variable length L1. For example, a 10 mm diameter generator with a length of 20 mm can hold approximately 1.5mL of a 10 wt% aqueous oxalic acid solution, or about 150 mg of oxalic acid, which can release approximately 120 cc of gas. In many applications the expected generation rate is less than 0.3 cc/day ; therefore such a generator could operate for 400 days. The length of container 1 can be reduced or increased, according to the needs of the application without the need for other dimensional changes. This is a feature of obvious interest to the manufacturer and the end-users. Further container volume reduction, or increased operating durations, can be achieved by using supersaturated mixtures of oxalic acid and water, containing more than 10 wt% of oxalic acid.
The assembly of the generator is simple, consisting of the following steps:
the plastic sleeve 1 is press-fitted into cap 2 B or the cap is crimped onto the sleeve; electrochemical cell 4 is placed within cathode cap 2 B; container 1 is filled with the appropriate amount of oxalic acid solution; spring 3 is inserted into container 1 ; in a separate operation, membrane 7 is inserted into anode cap 2 A, followed by seal 6 and retainer ring 5 , hereby completing the anode cap sub-assembly; and the sub-assembly is then press-fitted onto sleeve 1 .
The assembly process does not require complex tools or equipment and is readily amenable to automation.
When a current, or voltage, is applied to the anode and cathode caps, the following reactions take place:
Anode reaction: (COOH) 2 →CO 2 +2H + +2e −
Cathode reaction: 2H + +2e − →H2
Hydrogen evolves at the anode cap and is released from the oxalic acid solution through vent 8 . Carbon dioxide is released from the anodic surface of the electrochemical cell, bubbles through the solution and escapes via vent 8 . The generator is extremely efficient since 1.5 moles of gas are released for each electron, as compared to 0.5 mole of gas per electron for the hydrogen gas cell, 0.25 mole of gas per electron for the air-to-oxygen cell and 0.75 mole of gas per electron for the water electrolysis cell.
If H2 is an undesirable by-product, the assembly illustrated in FIG. 1 can be modified to prevent mixing of CO2 and H2, by providing a release port for H2 at the cathode. FIG. 4 illustrates such an assembly where a cathode seal 6 A is pressed against electrochemical cell 4 by means of a retainer ring SA. In this arrangement, H2 is prevented from bubbling through the oxalic acid solution, but allowed to be released through port 8 A provided for in cathode cap 2 C. In this instance, an external power source, battery 9 of FIG. 8 , is required to operate the gas generator. The second embodiment of FIG. 4 can also be used as a fuel cell power source or battery, where cap 2 C now serves as an oxygen cathode, while container 1 holds a fuel and cap 2 A becomes the fuel electrode or anode, In this instance, the following reactions will take place:
Air cathode reaction: O 2 (from air)+2H + +2e − →H 2 O
Fuel anode: Fuel→H + +e −
The fuels for the anodic reactions are generally inorganic compounds, such as metal hydrides, and organic compounds such as alcohols, ketones or acids. Carbonaceous fuels, such as methanol or oxalic acid, would require the presence of exit port 8 , since the reaction by-products would include volatile CO2. Non-carbonaceous fuels, such as sodium borohydride would not require an exit port since only solid by-products, such as sodium borate, are generated.
In either of these examples, the energy released by the over-all electrochemical process is sufficient to sustain the process. In the case of methanol, the anode reaction is: CH30H+H2O→CO2+6H + +6e − and the cathode reaction is: 6H + +6e − +1.5O2→3H2O for an over-all reaction of: CH3OH+H2O+1.5O2→CO2+3H2O which releases energy and CO2 gas. In this instance the auxiliary power source (battery) is not required. In conventional batteries, fuels and oxidants are solids capable of transferring electrons, or their electric conductivity is enhanced by grid structures or other materials to reduce internal resistance between the fuel, or oxidant and the current collectors. These batteries are not suitable for liquid fuels, such as methanol. By providing electric contacts by means of metal springs between the cell anode and metal cap 2 A of the structure of FIG. 4 , it is now possible to use liquid fuels in a structural embodiment similar to that of a battery.
When carbonaceous compounds are used, port 8 of FIG. 4 is used to evacuate CO2, whereas the gas port of bottom cap 2 c is used as an air intake port to allow the cathodic oxidation process, requiring oxygen from air, to take place. In this instance the energetic balance is such that electric power is generated simultaneously with gas generation. The CO2 generator does not require a battery, since it generates its own energy. Since cathode and anode materials are not consumed, the generator is a fuel cell, producing CO2 as a by-product.
When non-carbonaceous fuels, such as sodium borohydride, are used, port 8 is not required since CO2 is not being generated. FIG. 9 illustrates a simplified structure with an air intake port in bottom cap 2 C. Bottom cap 2 C becomes the air cathode of the fuel cell which in this instance generated electrochemical energy without producing gaseous by-products. FIG. 9 is a means to illustrate that the slightly modified structure can be used as a fuel cell.
FIG. 5 shows the experimental correlation between voltage and current for a gas generator of FIG. 1 holding a 0.06 cm 2 cell and decomposing an aqueous oxalic acid solution.
The operating cell voltage is below 1.0 volt for a current of up to 250 microamps or the equivalent of a current density of 4 milliamps/cm 2 . This low voltage is important since it allows the generator to operate from single batteries.
For high current densities, the internal resistance of the generator can be reduced by improving the contact between spring 3 and electrochemical cell 4 by intercalating a metal screen between spring 3 and cell 4 .
EXAMPLE I
A generator, as illustrated in FIG. 1 , is operated by means of a current controller described in FIG. 3 of U.S. Pat. No. 6,387,228 B1 and this current controller is incorporated in this patent application by reference. The generator is enclosed within a sealed container fitted with a pressure sensor. The pressure change is monitored as a function of time for three different currents, namely 50, 70 and 100 microamps. The observed pressure increases as a function of time and is proportional to the applied current, as illustrated in FIG. 6 .
EXAMPLE II
A generator, as illustrated in FIG. 1 , is equipped with a 0.06 cm 2 electrochemical cell and operated from a DC voltage of 1.43 volts applied directly to the terminals of the generator via a 30 kilo-ohm resistor. No other current or voltage regulation means are used. Current through the generator and generator voltage are monitored as a function of time. FIG. 7 illustrates the experimental results. In this instance the average electrochemical cell voltage over the test period is 0.80 volts with a maximum variance of +/−20 millivolts. This experiment suggests that current stability is achievable within 4% of the average value of 20.9 microamp, without controller, a result suggesting that for most applications no additional regulation is required.
For an application requiring a current of 20 microamps, a battery capacity of 14.4 mahr would be needed per month of operation. Since small commercial silver oxide batteries have a capacity of up to 120 mAhr, it is apparent that such a battery could operate the generator for at least six months, and that the container volume of 1.5 mL would be adequate to sustain such operation.
It should be apparent that various modifications of the described components and structures could be incorporated without affecting the spirit of the invention. Examples of such modifications are:
caps 2 A and/or 2 C to include “nipples” for the gas exit ports; spring geometries other than cylindrical, namely conical shapes; reversing the battery polarity at the generator caps, thereby forcing the release of gases to occur at different electrodes, while still exiting from the same port. Using various oxalic acid concentration, including supersaturated solutions Mixing oxalic acid with gelling agents to form solid gels.
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A miniature, battery-like device is described for the generation of gases or as a power source or battery. The generation of carbon dioxide and hydrogen by electrochemical decomposition of an aqueous oxalic acid solution is detailed. One of the electrodes of the internally located electrochemical cell is in intimate contact with the cathode cap of the device, while the other electrode is under compression from an internal spring of variable length which is in electrical contact with the anode cap. The low-cost device is easy to fill and assemble. It can be used for the controlled release of small quantities of fluid, delivered at low flow rates for long periods of time, such as pheromones, fragrances, insecticides, pesticides. It can also be used as power source using liquid fuels such as methanol and ambient air as a source of oxygen.
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RELATED APPLICATIONS
This is a divisional application of U.S. patent application Ser. No. 11/763,253, filed Jun. 14, 2007, entitled HIGH-TEMPERATURE, SPIN-ON, COMPOSITIONS FOR TEMPORARY WAFER BONDING USING SLIDING APPROACH, incorporated by reference herein. The '253 application claims the priority benefit of U.S. Provisional Patent Application No. 60/828,572, entitled HIGH-TEMPERATURE SPIN-ON ADHESIVES FOR TEMPORARY WAFER BONDING USING SLIDING APPROACH, filed Oct. 6, 2006, the entire disclosure of which is incorporated herein by reference.
GOVERNMENT FUNDING
This invention was made with government support under contract number W911SR-05-C-0019 awarded by the United States Army Research, Development, and Engineering Command. The United States Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention is broadly concerned with novel compositions and methods of using those compositions to form bonding compositions that can support active wafers on a carrier wafer or substrate during wafer thinning and other processing.
Description of the Prior Art
Wafer (substrate) thinning has been used to dissipate heat and aid in the electrical operation of the integrated circuits (IC). Thick substrates cause an increase in capacitance, requiring thicker transmission lines, and, in turn, a larger IC footprint. Substrate thinning increases impedance while capacitance decreases impedance, causing a reduction in transmission line thickness, and, in turn, a reduction in IC size. Thus, substrate thinning facilitates IC miniaturization.
Geometrical limitations are an additional incentive for substrate thinning. Via holes are etched on the backside of a substrate to facilitate frontside contacts. In order to construct a via using common dry-etch techniques, geometric restrictions apply. For substrate thicknesses of less than 100 μm, a via having a diameter of 30-70 μm is constructed using dry-etch methods that produce minimal post-etch residue within an acceptable time. For thick substrates, vias with larger diameters are needed. This requires longer dry-etch times and produces larger quantities of post-etch residue, thus significantly reducing throughput. Larger vias also require larger quantities of metallization, which is more costly. Therefore, for backside processing, thin substrates can be processed more quickly and at lower cost.
Thin substrates are also more easily cut and scribed into ICs. Thinner substrates have a smaller amount of material to penetrate and cut and there fore require less effort. No matter what method (sawing, scribe and break, or laser ablation) is used, ICs are easier to cut from thinner substrates. Most semiconductor wafers are thinned after frontside operations. For ease of handling, wafers are processed (i.e., frontside devices) at their normal full-size thicknesses, e.g., 600-700 μm. Once completed, they are thinned to thicknesses of 100-150 μm. In some cases (e.g., when hybrid substrates such as gallium arsenide (GaAs) are used for high-power devices) thicknesses may be taken down to 25 μm.
Mechanical substrate thinning is performed by bringing the wafer surface into contact with a hard and flat rotating horizontal platter that contains a liquid slurry. The slurry may contain abrasive media along with chemical etchants such as ammonia, fluoride, or combinations thereof. The abrasive provides “gross” substrate removal, i.e., thinning, while the etchant chemistry facilitates “polishing” at the submicron level. The wafer is maintained in contact with the media until an amount of substrate has been removed to achieve a targeted thickness.
For a wafer thickness of 300 μm or greater, the wafer is held in place with tooling that utilizes a vacuum chuck or some means of mechanical attachment. When wafer thickness is reduced to less than 300 μm, it becomes difficult or impossible to maintain control with regard to attachment and handling of the wafer during further thinning and processing. In some cases, mechanical devices may be made to attach and hold onto thinned wafers, however, they are subject to many problems, especially when processes may vary. For this reason, the wafers (“active” wafers) are mounted onto a separate rigid (carrier) substrate or wafer. This substrate becomes the holding platform for further thinning and post-thinning processing. Carrier substrates are composed of materials such as sapphire, quartz, certain glasses, and silicon, and usually exhibit a thickness of 1000 μm. Substrate choice will depend on how closely matched the coefficient of thermal expansion (CTE) is between each material.
One method that has been used to mount an active wafer to a carrier substrate comprises the use of a cured bonding composition. The major drawback with this approach is that the composition must be chemically removed, typically by dissolving in a solvent. This is very time-consuming, thus reducing throughput. Furthermore, the use of the solvent adds to the cost and complexity of the process, and it can be hazardous, depending upon the solvent required to dissolve the bonding composition.
Another method for mounting an active wafer to a carrier substrate is via a thermal release adhesive tape. This process has two major shortcomings. First, the tapes have limited thickness uniformity across the active wafer/carrier substrate interface, and this limited uniformity is often inadequate for ultra-thin wafer handling. Second, the thermal release adhesive softens at such low temperatures that the bonded wafer/carrier substrate stack cannot withstand many typical wafer processing steps that are carried out at higher temperatures.
There is a need for new compositions and methods of adhering an active wafer to a carrier substrate that can endure high processing temperatures and that allow for ready separation of the wafer and substrate at the appropriate stage of the process.
SUMMARY OF THE INVENTION
In one embodiment, the present invention is a wafer bonding method wherein a stack comprising first and second substrates bonded together via a bonding layer is preferably subjected to various processing steps (e.g., wafer thinning). The processed stack is then heated to a temperature of at least about 190° C., and a sliding force is applied to at least one of the substrates while causing the other of the substrates to resist the force, such as by securing the other substrate or subjecting it to an opposing force. The force is applied in a sufficient amount so as to separate the substrates.
In another embodiment, the invention provides an article comprising: a first substrate having a hack surface and an active surface; a second substrate having a bonding surface; and bonding layer bonded to the active and bonding surfaces.
In one embodiment, the bonding layer is formed of a composition comprising a polymer (or polymer blend) and a tackifier such as a pinene or poly(pinene) dissolved or dispersed in a solvent system, with the polymer including recurring monomers comprising cyclo olefins.
In another embodiment, the invention provides a flowable, bonding composition comprising a tackifier and a polymer including recurring monomers comprising cyclo-olefins. The tackifier and polymer are dispersed or dissolved in a solvent system that makes up at least about 30% by weight of the composition, based upon the total weight of the composition taken as 100% by weight.
In one embodiment, a flowable, bonding composition comprising a tackifier and a compound selected from the group consisting of rubbers, styrene-isoprene-styrene, styrene-butadiene-styrene, halogenated butyl rubber, and mixtures thereof is provided. The tackifier and compound are dispersed or dissolved in a solvent system that makes up at least about 30% by weight of the composition, based upon the total weight of the composition taken as 100% by weight.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 illustrates the inventive method of thinning and debonding two wafers according to the present invention;
FIG. 2 is a flow diagram showing the process steps followed in the examples;
FIG. 3 is a graph depicting the rheological analysis results of a bonding composition described in Example 1;
FIG. 4 is a graph depicting the rheological analysis results of a bonding composition described in Example 2;
FIG. 5 is a graph depicting the rheological analysis results of a bonding composition described in Example 3; and
FIG. 6 is a graph depicting the rheological analysis results of a bonding composition described in Example 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In more detail, the inventive compositions comprise a polymer (which includes a polymer mixture) dispersed or dissolved in a solvent system. The polymer is preferably present in the composition at levels of from about 5% to about 50% by weight, more preferably from about 5% to about 35% by weight, and even more preferably from about 10% to about 35% by weight, based upon the total weight of solids in the composition taken as 100% by weight.
The preferred polymers are thermoplastic and preferably have a weight average molecular weight of from about 500 Daltons to about 1,000,000 Daltons, and more preferably from about 1,000 Daltons to about 500,000 Daltons. Preferred polymers preferably have a softening point (ring and ball softening point) of at least about 50° C., more preferably at least about 100° C., and even more preferably from about 100° C. to about 200° C.
Preferred polymers will be at least about 95%, preferably at least about 98%, and even more preferably about 100% by weight dissolved when allowed to sit at ambient temperatures in a solvent such as limonene, mesitylene, xylene, methyl isoamyl ketone, ethyl acetoacetate, and/or dodecene for a time period of about 1-24 hours.
Some preferred polymers that work in the present invention include those selected from the group consisting of cellulose polymers (such as cellulose acetate polymers), cyclo olefin polymers (such as those sold under the name Zeonex®), rubbers (ethylene-propylene terpolymers (EPM), ethylene-propylene-diene monomers (EPDM)), styrene-isoprene-styrene, styrene-butadiene-styrene, polyolefins, ethylene-vinyl acetate, halogenated butyl rubber, and mixtures thereof.
The composition should comprise at least about 30% by weight solvent system, preferably from about 50 to about 95% by weight solvent system, more preferably from about 65-95% by weight solvent system, and even more preferably from about 65-90% by weight solvent system, based upon the total weight of the composition taken as 100% by weight. The solvent system should have a boiling point of from about 100-200° C., and preferably from about 120-180° C.
Suitable solvents include those selected from the group consisting of limonene (particularly D-limonene), mesitylene, xylene, dodecene, propylene glycol monomethyl ether, methyl isoamyl ketone, ethyl acetoacetate, and mixtures thereof.
In other embodiments, the composition could include a number of optional ingredients, including surfactants, adhesion promoting agents, tackifiers, plasticizer, and antioxidants.
When a surfactant is utilized, it is preferably present in the composition at a level of from about 0.1% to about 3% by weight, and more preferably from about 0.1% to about 1% by weight, based upon the total weight of the solids in the composition taken as 100% by weight. Examples of suitable surfactants include alcohol ethoxylates such as octyl phenol ethoxylate (sold under the name Triton X-100®).
When an adhesion promoting agent is utilized, it is preferably present in the composition at a level of from about 0.1% to about 3% by weight, and preferably from about 0.1% to about 1% by weight, based upon the total weight of the solids in the composition taken as 100% by weight. Examples of suitable adhesion promoting agent include those selected from the group consisting of bis(trimethoxysilylethyl)benzene, aminopropyl tri(alkoxy silanes) (e.g., aminopropyl tri(methoxy silane), aminopropyl tri(ethoxy silanes), N-phenyl aminopropyl tri(ethoxy silane)), and other silane coupling agents.
When a tackifier is utilized, it is preferably present in the composition at a level of from about 50% to about 95% by weight, and preferably from about 75% to about 95% by weight, based upon the total weight of the solids in the composition taken as 100% by weight. The tackifier is preferably a hydrocarbon resin (polymeric and/or monomeric) and preferably has an M w of from about 300-10,000 Daltons, and more preferably from about 500-5,000 Daltons. Preferred hydrocarbon resins have a softening point (ring and ball softening point) of at least about 80° C., and more preferably from about 120-200° C. Furthermore, it is preferred that the hydrocarbon resin have a Brookfield viscosity at 190° C. of from about 2,500-3,500 cP, preferably from about 2,800-3,200 cP, and even more preferably about 2,900-3,100 cP, Suitable tackifiers include all aliphatic hydrocarbon resins, aromatic hydrocarbon resins, and aliphatic/aromatic hydrocarbon resins as well as those selected from the group consisting of rosins (e.g., terpene rosins), poly(α-pinene), poly(β-pinene), and mixtures thereof. Particularly preferred hydrocarbon resins are sold under the names EASTOTAC, PICCOTAC, and REGALREZ, all available from Eastman Chemical Company.
When an antioxidant is utilized, it is preferably present in the composition at a level of from about 0.01% to about 3% by weight, more preferably from about 0.01% to about 1.5% by weight, and even more preferably from about 0.01% to about 0.1% by weight, based upon the total weight of the solids in the composition taken as 100% by weight. Examples of suitable antioxidants include those selected from the group consisting of phenolic antioxidants (such as pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate sold under the name Irganox® 1010 by Ciba) and phosphite antioxidants (such as tris(2,4-ditert-butylphenyl)phosphite sold under the name Irgafos® 168 by Ciba).
The inventive compositions are formed by simply mixing the polymer and other ingredients with the solvent system, preferably at temperatures of from about 20-80° C. for time periods of from about 1-24 hours. The final composition should be thermoplastic (i.e., noncrosslinkable). Thus, the composition will be essentially free (less than about 0.1% by weight and preferably about 0% by weight) of crosslinking agents.
Furthermore, it is preferred that the final composition undergo little or no (i.e., less than about 3%) expansion or change in volume during exposure to different temperatures. To accomplish this, the composition is preferably essentially free (less than about 0.1% by weight and preferably about 0% by weight) of blowing agents and foaming agents. Blowing and foaming agents are compounds that will decompose and release substantial amounts gas under certain conditions (e.g., exposure to high temperatures).
The final compositions will preferably have a Mooney Viscosity (ML (1+4) 125° C.; as determined by ISO289/ASTM D 1646) of less than about 35 MU, preferably less than about 30 MU, and even more preferably from about 5 to about 25 MU.
The viscosity of the final composition will preferably be less than about 1,000 poise, more preferably less than about 500, and even more preferably from about 30 to about 100 poise. For purposes of these measurements, the viscosity is determined via rheological dynamic analysis (TA Instruments, AR-2000, two parallel-plate configuration where the plates have a diameter of 25 mm). Furthermore, this viscosity is determined at 250° C. and there is preferably less than about 3% by weight, and more preferably less than about 2% by weight, loss of the composition. In other words, very little to no thermal decomposition occurs in the composition at this temperature, as determined by thermogravimetric analysis (TGA).
Although the composition could be applied to either the carrier substrate or active wafer first, it is preferred that it be applied to the active wafer first. A preferred application method involves spin-coating the composition at spin speeds of from about 300-3,500 rpm (more preferably from about 500-1,500 rpm), at accelerations of from about 500-15,000 rpm/second, and for spin times of from about 30-300 seconds. It will be appreciated that the application steps can be varied to achieve a particular thickness.
After coating, the substrate can be baked (e.g., on a hot plate) to evaporate the solvents. Typical baking would be at temperatures of from about 150-275° C., and preferably from about 150-225° C. for a time period of from about 2-15 minutes, and more preferably from about 3-10 minutes. The film thickness (on top of the topography) after bake will typically be at least about 5 μm, and more preferably from about 5-50 μm.
After baking, the desired carrier wafer is contacted with, and pressed against, the layer of inventive composition. The carrier wafer is bonded to this inventive composition by heating at a temperature of from about 150-250° C., and preferably from about 180-220° C. This heating is preferably carried out under vacuum and for a time period of from about 1-10 minutes, under a bond force of from about 1 to about 15 kilonewtons.
FIG. 1( a ) shows an exemplary stack 10 comprising active wafer 12 and carrier wafer or substrate 14 . Active wafer 12 comprises a back surface 16 and an active surface 18 . Active surface 18 can comprise one or more active sites (not shown) as well as a plurality of topographical features (raised features or lines as well as holes, trenches, or spaces) such as, for example, those designated as 20 a - d . Feature 20 d represents the “highest” feature on active surface 18 . That is, the end portion or surface 21 is further from back surface 16 of wafer 12 than the respective end portions of any other topographical feature on wafer 12 .
Typical active wafers 12 can include any microelectronic substrate. Examples of some possible active wafers 12 include those selected from the group consisting of microelectromechanical system (MEMS) devices, display devices, flexible substrates (e.g., cured epoxy substrates, roll-up substrates that can be used to form maps), compound semiconductors, low k dielectric layers, dielectric layers (e.g., silicon oxide, silicon nitride), ion implant layers, and substrates comprising silicon, aluminum, tungsten, tungsten silicide, gallium arsenide, germanium, tantalum, tantalum nitrite, SiGe, and mixtures of the foregoing.
Carrier substrate 14 has a bonding surface 22 . Typical carrier substrates 14 comprise a material selected From the group consisting of sapphire, ceramic, glass, quartz, aluminum, silver, and silicon.
Wafer 12 and carrier substrate 14 are bonded together via bonding composition layer 24 . Bonding layer 24 is formed of the polymer compositions described above, and has been applied and dried as also described above. As shown in the FIG. 1( a ) , bonding layer 24 is bonded to active surface 18 of wafer 12 as well as to bonding surface 22 of substrate 14 . Unlike prior art tapes, bonding layer 24 is a uniform (chemically the same) material across its thickness. In other words, the entire bonding layer 24 is formed of the same composition.
It will be appreciated that, because bonding layer 24 can be applied to active surface 18 by spincoating, the bonding composition flows into and over the various topographical features. Furthermore, the bonding layer 24 forms a uniform layer over the topography of active surface 18 . To illustrate this point, FIG. 1 shows a plane designated by dashed line 26 , at end portion 21 and substantially parallel to back surface 16 . The distance from this plane to bonding surface 22 is represented by the thickness “T.” The thickness T is the total thickness variation, and it will vary by less than about 8%, preferably by less than about 5%, more preferably by less than about 2%, and even more preferably by less than about 1% across the length of plane 26 and substrate 14 .
The wafer package can then be subjected to subsequent thinning (or other processing) of the substrate as shown in FIG. 1( b ) , where 12 ′ presents the wafer 12 after thinning. It will be appreciated that the substrates can be thinned to thicknesses of less than about 100 μm, preferably less than about 50 μm, and more preferably less than about 25 μm. After thinning, typical backside processing, including photolithography, via etching, and metallization, may be performed.
Advantageously, the dried layers of the inventive compositions possess a number of highly desirable properties. For example, the layers will exhibit low outgassing for vacuum etch processes. That is, if a 15-μm thick film of composition is baked at 200° C. for 2 minutes, the solvents will be driven from the composition so that subsequent baking at 200° C. for 60 minutes results in a film thickness change of less than about 5%, preferably less than about 2%, and even more preferably less than about 1% or even 0% (referred to as the “Film Shrinkage Test”). Thus, the dried layers can be heated to temperatures of up to about 190° C., preferably up to about 200° C., more preferably up to about 220° C., and even more preferably up to about 240° C. without physical changes or chemical reactions occurring in the layer. For example, the layers will not soften below these temperatures. In some embodiments, the layers can also be exposed to polar solvents (e.g., NMP, PGME) at a temperature of 85° C. for 90 minutes without reacting.
The bond integrity of the dried layers can be maintained even upon exposure to an acid or base. That is, a dried layer of the composition having a thickness of about 15 μm can be submerged in an acidic media (e.g., concentrated sulfuric acid) or base (e.g., 30 wt. % KOH) at 85° C. for about 45 minutes while maintaining bond integrity. Bond integrity can be evaluation by using a glass carrier substrate and visually observing the bonding composition layer through the glass carrier substrate to check for bubbles, voids, etc. Also, bond integrity is maintained if the active wafer and carrier substrate cannot be separated by hand.
The bonding compositions are also thermally stable. When subjected to the thermogravimetric analysis (TGA) test described herein, the bonding compositions will exhibit a % weight loss (after 200° C. for 60 min) of less than about 4%, preferably less than about 2%, and even more preferably less than about 1%.
After the desired processing has occurred, the active wafer or substrate can be separated from the carrier substrate by heating to temperatures of at least about 190° C., preferably at least about 200° C., more preferably at least about 220° C., and even more preferably at least about 240° C. These temperature ranges represent the preferred softening points of the bonding composition layer. This heating will cause the bonding composition layer to soften and form softened bonding composition layer 24 ′ as shown in FIG. 1( c ) , at which point the two substrates can be separated by sliding apart. FIG. 1( c ) also shows an axis 28 , which passes through both of wafer 12 and substrate 14 , and the sliding forces would be applied in a direction generally transverse to axis 28 . Alternatively, sliding may not be necessary, and instead wafer 12 or substrate 14 can be lifted upward (i.e., in a direction that is generally away from the other of wafer 12 or substrate 14 ) to separate the wafer 12 from the substrate 14 .
It will be appreciated that separation can be accomplished by simply sliding and/or lifting one of wafer 12 or substrate 14 while maintaining the other in a substantially stationary position so as to resist the sliding or lifting force (e.g., by applying simultaneous opposing sliding forces to wafer 12 and substrate 14 ). This can all be accomplished via conventional equipment.
Any bonding composition remaining in the device areas can be easily removed using the original solvent that was part of the composition prior to drying as well as using solvents such as xylene, benzene, and limonene. Any composition remaining behind will be completely dissolved (at least about 98%, preferably at least about 99%, and more preferably about 100%) after 5-15 minutes of exposure to the solvent. It is also acceptable to remove any remaining bonding composition using a plasma etch, either alone or in combination with a solvent removal process. After this step, a clean, bonding composition-free wafer 12 ′ and carrier substrate 14 (not shown in their clean state) will remain.
EXAMPLES
The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
Example 1
Formulations were made by dissolving various cellulose derivatives (obtained from Eastman Chemical Company, Kingsport, Tenn.) in appropriate solvents. The exact materials and quantities used are reported in Table I.
TABLE I
Bonding Composition Formulations from Cellulose Materials.
SAMPLE
SAMPLE
SAMPLE
SAMPLE
INGREDIENTS
1.1 (g)
1.2 (g)
1.3 (g)
1.4 (g)
Cellulose acetate (29.5%)
20
0
0
0
butyrate (17%)
Cellulose acetate
0
18
0
0
trimelliate
Cellulose acetate (2%)
0
0
25
0
butyrate (52%)
Cellulose acetate (18.5%)
0
0
0
25
butyrate (31%)
Propylene glycol
0
82
0
0
monomethyl ether
Methyl isoamyl ketone
50
0
75
50
Ethyl acetoacetate
30
0
0
25
Example 2
Cycloolefin Resin and Poly(α-Pinene) Blend
Formulations were made by dissolving Zeonex 480R resin (obtained from Zeon Chemicals, Louisville, Ky.) and/or poly(α-pinene) (obtained from Aldrich, Milwaukee, Wis.) and/or poly(β-pinene) (obtained from Aldrich, Milwaukee, Wis.) in D-limonene (obtained from Florida Chemical Company). Bis(trimethoxysilylethyl)benzene (obtained from Aldrich, Milwaukee, Wis.) was added as an adhesion promoter. The exact compositions of the formulations are reported in Table II.
TABLE II
Bonding Composition Formulations from
Poly(cycloolefin) and Pinene Materials.
SAMPLE
SAMPLE
SAMPLE
SAMPLE
INGREDIENTS
2.1 (g)
2.2 (g)
2.3 (g)
2.4 (g)
Zeonex 480R
120
55.9
46.05
20
Poly(α-pinene)
0
14.3
30.7
0
Poly(β-pinene)
0
0
0
5
D-limonene
280
144.8
138.15
74.875
Bis(trimethoxysilyl-
0.5
0.268
0.268
0.125
ethyl)benzene
Example 3
Cycloolefin Resin and Rosin Ester Blend
The formulations were made by dissolving Zeonex 480R resin and Eastotac H142W (obtained from Eastman Chemicals, Kingsport, Tenn.) in a suitable solvent. Irganox 1010 and Irgafos 168 (obtained from Ciba Specialty Chemicals, Tarrytown, N.Y.) were added to one of the formulations to prevent thermal oxidation at high temperatures. Triton X-100 (obtained from Aldrich, Milwaukee, Wis.) was added to reduce de-wetting problems, and bis(trimethoxysilylethyl)benzene was added to promote adhesion. The exact compositions of the formulations are reported in Table III.
TABLE III
Bonding Composition Formulations Based on
Poly(cycloolefin) and Rosin Ester Blends.
SAMPLE
SAMPLE
SAMPLE
SAMPLE
INGREDIENTS
3.1 (g)
3.2 (g)
3.3 (g)
3.4 (g)
Zeonex 480R
3
5
g
7
40
Eastotac H142W
7
5
3
160
D-limonene
12
30
30
60
Mesitylene
0
0
0
140
Irganox 1010
0
0
0
2
Irgafos 168
0
0
0
1
Triton X-100
0
0
0
1
Bis(trimethoxysilyl-
0
0
0
1
ethyl)benzene
Example 4
EPDM Rubber and Rosin Ester Blend
The formulations were made by dissolving different grades of ethylene propylene diene monomer rubber (EPDM rubber: Buna EP T6250, obtained from Lanxess, Inc., Pittsburgh, Pa.; and Vistalon 2504, Exxon-Mobil Chemical, Houston, Tex.) and Eastotac H142W in a suitable solvent. The antioxidant Irganox 1010 was added to three of the four formulations. The exact compositions of the formulations are reported in Table IV.
TABLE IV
Bonding Composition Formulations Based
on EPDM Rubber and Rosin Ester Blends.
SAMPLE
SAMPLE
SAMPLE
SAMPLE
INGREDIENTS
4.1 (g)
4.2 (g)
4.3 (g)
4.4 (g)
Buna EPT 6250
0.6
1
0
0
Vistalon 2504
0
0
3.7
19.425
Zeonex 480R
3.4
3
0
0
Eastotac H142W
16
16
11.1
91.575
D-limonene
20
20
25
189
Irganox 1010
0.2
0.2
0
1.11
Example 5
Application, Bonding, and Debonding
The formulations from Examples 1-4 were spin-coated onto various substrate wafers. After baking to evaporate the solvent and allowing the bonding composition to reflow, a second wafer was bonded to each coated wafer by applying pressure. The procedure for temporary wafer bonding using these bonding compositions is illustrated in the flow diagram shown in FIG. 2 . The bonded wafers were tested for mechanical strength, thermal stability, and chemical resistance. The wafers were tested for debonding by manually sliding them apart at acceptable temperatures.
Example 6
Analysis of the Bonding Compositions
From a rheological analysis, the compositions of Samples 1.4, 2.2, 3.4, and 4.4 were identified as the preferred materials for temporary wafer bonding. FIGS. 3, 4, 5 , and 6 shows these results for Samples 1.4, 2.4, 3.4, and 4.4, respectively. The viscosity and modulus values of these materials are reported in Table V, and these materials were successfully tested for debonding. Further studies on thermal stability and chemical resistance were also carried out on these four compositions as described below.
Thermogravimetric analysis (TGA) was carried out on a TA Instruments thermogravimetric analyzer. The TGA samples were obtained by scraping the spincoated and baked bonding composition samples listed in examples. The samples were heated at a rate of 10° C./minute, up to 200° C., and kept constantly at 200° C. for longer periods of time to determine the thermal stability of the particular bonding composition. All of these compositions possessed the required thermal stability at 200° C. and exhibited minimal outgassing (see Table VI).
To determine chemical resistance, two silicon wafers were bonded using the particular bonding composition to be tested. The bonded wafers were put into chemical baths of NMP or 30 wt. % KOH at 85° C., and concentrated sulfuric acid at room temperature to determine chemical resistance. The bond integrity was visually observed after 45 minutes, and the stability of the bonding composition against the respective chemical was determined. All bonding compositions, except for Sample 1.4, retained the bond integrity.
TABLE V
Storage Modulus and Viscosity Values of Bonding Compositions
G′ (dynes/cm 2 )
h at 200° C.
Sample Number
at 200° C.
(poise)
1.4
270
244
2.2
2026
1782
3.4
736.5
847
4.4
463
210
TABLE VI
Isothermal Thermogravimetric Results - Thermal
Stability of Bonding Compositions.
% Weight loss
Sample Number
(200° C./60 min)
Example 1.4
0.23
Example 2.2
0.35
Example 3.4
1.5
Example 4.4
2
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New compositions and methods of using those compositions as bonding compositions are provided. The compositions comprise a polymer dispersed or dissolved in a solvent system, and can be used to bond an active wafer to a carrier wafer or substrate to assist in protecting the active wafer and its active sites during subsequent processing and handling. The compositions form bonding layers that are chemically and thermally resistant, but that can also be softened to allow the wafers to slide apart at the appropriate stage in the fabrication process.
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[0001] This application claims benefit under 35 U.S.C. 119(e) of a prior U.S. provisional application Ser. No. 60/515654 filed on Oct. 31, 2003 and is a continuation-in-part application thereof, all of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to firearms and, more specifically, is concerned with an apparatus for holding a firearm onto the leg of the user. The disclosed invention is particularly well-suited for persons used to walking or hunting while carrying firearms.
[0004] 2. Description of the Prior Art
[0005] Devices for holding firearms have been described in the prior art; however, none of the prior art devices disclose the unique features of the present invention.
[0006] In U.S. Pat. No. 5,058,788, dated Oct. 22, 1991, Newmark disclosed a first wrap adapted to wrap around the lower leg generally over the medial malleolus and above the lateral malleolus which is connected by a strap to a second wrap adapted to wrap around the lower leg generally on the upper portion of the gastroenemius or below the popliteal fossa. The first wrap has a holster for carrying a firearm and which holster is secured approximately over the medial malleolus. The holster may be selectively detachable to allow a selection of holsters to be secured to the first wrap. The second wrap carries the substantial portion of the weight of the load of the assembly, and of any holster and firearm secured thereto.
[0007] In U.S. Pat. No. 5,819,320, dated Oct. 13, 1998, Jolla disclosed a detachable trouser garment which allows police officers the ability to use restroom facilities without removing their firearm. The garment has a waist portion, a detachable portion and a horizontal fastening mechanism for selectively attaching both portions. The waist portion contains a plurality of belt loops to accept a standard belt and a firearm belt attachment to accept a firearm belt. A user opens the fastening mechanism prior to using restroom facilities. The detachable portion of the garment can then be lowered while the waist portion remains undisturbed. This allows the firearm to remain in proper position around the waist at all times.
[0008] In U.S. Pat. No. 5,765,738, dated Jun. 16, 1998, Hoffner disclosed a harness for supporting a handgun holster adjacent the thigh of a wearer in a position relative to the wearer's torso which is maintained even though the wearer may be engaged in vigorous activity and precludes shifting of the holster as would disadvantage the wearer in an emergency situation. The harness includes a waist belt and at least one or a pair of substantially rigid shankpieces mounted to the waist belt to extend downwardly alongside the respective thighs of the harness wearer. On the lower end of each shankpiece is fastened a leg strap for tightening about the wearer's leg adjacent thereto and precluding shifting of the waist belt and shankpieces relative to the torso. The handgun holster is mounted on the outside of one of the shankpieces to extend downwardly alongside the thigh in offset relation thereto.
[0009] In U.S. Pat. No. 5,718,363, Feb. 17, 1998, Graves disclosed a firearm carrier for safely transporting firearms. The carrier transversely secures the firearm to a user's body while preventing accidental discharges of the firearm. The firearm carrier is particularly well suited for use on an ATV. The firearm carrier safely, temporarily attaches the firearm to the user's waist in a safe, stable transport configuration. The firearm carrier may also be used as a temporary shoulder sling. The firearm carrier comprises an elongated, adjustable belt that fits around the waist of the user. A quick release buckle system facilitates belt removal. A pair of spaced apart straps project downwardly from the belt. Preferably, the straps project downwardly along the front of the user's legs. Each strap extends to a terminal end. An intermediary leg projects from each strap. Preferably, the straps are appropriately covered by a hook and pile fasteners. The straps encircle the gun during deployment, forming a pair of retention loops t hat secure the gun to the user's waist. To attach the gun to the carrier, the gun is placed against the strap interior and the intermediary leg is looped over the gun. Then the terminal end is placed on top of the intermediary leg and tightly fastened to form a retention loop. A trigger guard system prevents an accidental discharge of the firearm. The trigger guard system optionally attaches t either of the straps about the respective retention loop. The trigger guard system prevents accident discharge.
[0010] In U.S. Pat. No. 5,715,979, dated Feb. 10, 1998, Crandall disclosed a sling which is used to support rifles during aiming and firing which respond to the blood pressure pulse in the shooter's upper arm resulting in rhythmic stress in the straps which extend to connect with the rifle. This is caused by the position and singular nature of the prior attachment between that portion of the sling surrounding the shooter's upper arm and that portion of the sling which extends to the rifle. This interaction between the prior art slings and the shooter's pulse results in movement of the rifle and a reduction in practical accuracy. Slings of the present invention incorporate two attachments to that portion of the sling system which surrounds the shooter's arm and two non parallel straps extending to the rifle. By virtue of the location of these two attachments, the shooter's pulse can no longer create rhythmic stress in the straps extending to the rifle. Motion of the rifle during aiming and firing is reduced and practical accuracy is increased.
[0011] In U.S. Pat. No. 6,375,052 B2, dated Apr. 23, 2002, Keton disclosed a pair of Nylon straps adapted for holding and readily releasing a firearm or bow across a hunter's lap while sitting on the ground or in a tree. Each nylon strap is formed from a leg strap and a weapon retainer strap of nylon webbing material attached together in cruciform fashion. The ends of each nylon strap have hook and loop material attached thereto. The leg strap is wrapped around the hunter's leg, the weapon retainer strap is wrapped around the firearm or bow. One strap is placed around the right leg and the other strap is placed around the left leg, the straps securing opposite ends of the firearm or bow, leaving the hunter's hands free while keeping the weapon readily accessible.
[0012] In U.S. Pat. No. 6,336,226 B1 dated Jan. 8, 2002, Garcia disclosed a convertible garment and method for providing pants that may be converted into a satchel, backpack, gun case or pillow. The convertible garment and method includes a pair of pants having a first leg portion, a second leg portion and a lower torso portion. Each of the first and second leg portions is integrally coupled to and extends away from the lower torso portion. Each of the plurality of drawstrings is used for cinching various portions of the pants. A first of the drawstrings is attached to a free end of the first leg portion. A second of the drawstrings is attached to a free end of the second leg portion. A third of the drawstrings is attached to the first leg portion and positioned generally adjacent to the lower torso portion, and a fourth of the drawstrings is attached to the second leg portion and positioned generally adjacent to the lower torso portion.
[0013] In U.S. Pat. No. 6,260,209 B1, dated Jul. 171, 2001, St. Ange disclosed a pants assembly including an upper portion dimensioned and configured to be secured in substantially surrounding relation about the wearer's waist and a lower portion depending downwardly from the upper portion in covering relation to a lower torso and at least an upper leg portion of the wearer depending upon the length of each pant leg. The pants assembly is particularly designed for use b law enforcement or other uniformed personnel as part of a standard uniform which requires the additional wearing of utility or gun belt structured to be secured about the exterior surface of the upper portion and designed to hold a handgun, radio, hand-cuffs, and/or a number of other devices used in the performance of the person's duties. An attachment assembly is provided for interconnection and at least partial, selective separation of the inner leg seam lines from one leg to the next in order to facilitate the access of the wearer to toilet facilities without requiring the removal of the upper portion of the pants assembly and accordingly, the gun belt or other utility belt attached therein.
[0014] In U.S. Pat. No. U.S. 2002/0020723 A1, dated Feb. 21, 2002, Lindsey disclosed an upper sling attachment adapter for M-16 rifles and M-4 carbines and other utilizing a front sight having at least one leg extending at one end from near the end of the weapon barrel to, at its other end, the front sight of the weapon and having right and left sides with respect to the weapon, the improvement comprising a sling attachment means encircling and clamping said leg and extending along at least one of the right or left sides of the said leg, said sling attachment means having upper sling mount means to which the upper end of a weapon sling is attached, said upper sling mount means being suspended by said attachment means and extending away from said leg so that the upper end of the weapons sling is held away form the slight line of the front sight.
[0015] In U.S. Pat. Pub. No. US 2001/10030211 A 1, dated Oct. 18, 2001, Keton disclosed weapon holding straps which are a pair of nylon straps adapted for holding and readily releasing a firearm or bow across a hunter's lap while sitting on the ground or in a tree. Each nylon strap is formed from a leg strap and a weapon retainer strap of nylon webbing material attached together in cruciform fashion. The ends of each nylon strap have hook and loop material attached thereon. The leg strap is wrapped around the hunter's leg, the weapon retainer strap is wrapped around the firearm or bow. One strap is placed around the right leg and the other scrap is placed around the left leg, the straps securing opposite ends of the firearm or bow, leaving the hunter's hands free while keeping the weapon readily accessible.
[0016] While these devices for holding firearms may be suitable for the purposes for which they were designed, they would not be as suitable for the purposes of the present invention, as hereinafter described.
SUMMARY OF THE PRESENT INVENTION
[0017] The present invention discloses an apparatus for holding a firearm onto the leg of a user comprising a pair of adjustable shafts being adjustable in length, which run longitudinally along the lower leg of the user having upper and lower straps which attach to the leg of the user. The lower portion of one shaft has a plastic holder for receiving the butt of the firearm and an upper arm for receiving a barrel of the firearm so that the firearm is angled away from the body of the user.
[0018] An object of the present invention is to provide a weapon holder for attachment to the leg of a user so as to free the hands of a user. A further object of the present invention is to allow a standing hunter to have ready access to a weapon without having to hold the weapon in his hands. A further object of the present invention is to allow the user of the present invention to be mobile while having the present invention strapped to his leg. A further object of the present invention is to allow a hunter from holding a cold weapon as normally occurs in a prior art situation on cold days.
[0019] The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings in which:
[0021] FIG. 1 is a perspective view of the present invention.
[0022] FIG. 2 is a perspective view of the present invention.
LIST OF REFERENCE NUMERALS
[0023] With regard to reference numerals used, the following numbering is used throughout the drawings.
10 present invention 12 leg 14 first shaft 15 second shaft 16 upper leg strap (thigh strap) 18 lower leg strap (calf/calves strap) 20 foot strap 22 holder 24 butt 26 rifle 28 barrel 30 barrel holder 32 foot plate 36 length adjuster
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] The firearm holding apparatus of the present application is designed for a user such as hunter and military or police personnel to strap on the firearm in the firearm holding apparatus to his or her leg allowing the user to maintain a hands-free posture while having easy access to the weapon. It is also allows the user to be mobile while carrying the firearm in the firearm holding apparatus. For example, it is useful for the user such as hunter or a police guard to carry the firearm while walking during a hunt or a guard duty without having to carry the firearm but having the firearm within easy access and reach.
[0039] Turning to FIGS. 1 and 2 , shown therein is the present invention being an apparatus for attachment to the leg 12 of a user. The present invention 10 has first and second generally upright standing shafts or poles 14 , 15 having means for adjustment or pole adjusters 36 so that the length of the shafts 14 , 15 can be varied to suit the requirements of the user. The shaft 14 is mounted generally longitudinally along the leg 12 of the user having an upper strap (thigh strap) 16 and a pair of lower straps (calf or calves strap) 18 and a foot strap 20 which encircles or wraps around the leg 12 and foot 20 of the user. The length of the straps 16 , 18 , and 20 may be easily adjusted around the leg and foot 12 , 21 of the user using means for adjustment not limited to hook and loop material, hook and pile fasteners such as VELCRO or a buckle. Attached to the bottom end of shaft 14 is a holder 22 for receiving the butt 24 of the weapon 26 therein. Holder 22 has a foot plate 32 thereon which is disposed under the foot 21 of the user to help secure it to foot 21 . A second shaft 15 is attached to the front end of the gun butt holder 22 in a generally upright manner and is angled away from the leg 12 so as to allow the user to easily access the weapon 26 therein. The angle ranges from zero to 25 degrees preferably 5-20 degrees away from the user within the easy reach of the user. The barrel 28 of the rifle 26 is inserted into a hook-like holder 30 which is attached to the upper end of the shaft 15 . The holder 30 is shaped in a manner that secures the barrel to the holder not limited to a hook-like shape. The inside diameter of the hook 30 may have sponge or the like material which secures the barrel 28 therein so as to prevent abrasions or any damage to the barrel. The straps 16 , 18 and 20 may be made of durable weather-resistant material including but not limited to nylon. The present invention 10 may be comprised of plastic or the like weather-resistant and durable material.
DEFINITIONS
[0040] It must be noted that as used herein and in the appended claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise.
[0041] “Angled away” is defined as 0-25 degrees alignment away from the longitudinal axis of body of the user.
[0042] “Durable” is defined as designed to exist for a long time without significant deterioration.
[0043] “Weather-resistant” is defined as designed to exist for a long time without significant deterioration went exposed to inclement weather such as rain water, temperatures higher than 30 degrees Celsius and below 10 degrees Celsius, humidity higher than 85% and corrosive atmosphere.
[0044] “Protective material” is defined as a material designed to protect from damage not limited to cuts, scratches/abrasions, breakage and dents.
EXAMPLE
[0045] The following discussion describes in detail one embodiment of the present invention. This discussion should not be construed, however, as limiting the invention to those particular embodiments since practitioners skilled in the art will recognize numerous other embodiments as well.
[0046] Turning to FIGS. 1 and 2 , shown therein is the present invention being an apparatus for attachment to the leg 12 of a user. The present invention 10 has first and second generally upright standing shafts or poles 14 , 15 having means for adjustment or pole adjusters 36 so that the length of the shafts 14 , 15 can be varied to suit the requirements of the user. The shaft 14 is mounted generally longitudinally along the leg 12 of the user having an upper strap (thigh strap) 16 and a pair of lower straps (calf or calves strap) 18 and a foot strap 20 which encircles or wraps around the leg 12 and foot 20 of the user. The length of the straps 16 , 18 , and 20 may be easily adjusted around the leg and foot 12 , 21 of the user using hook and loop materials. Attached to the bottom end of shaft 14 is a holder 22 for receiving the butt 24 of the weapon 26 therein. Holder 22 has a foot plate 32 thereon which is disposed under the foot 21 of the user to help secure it to foot 21 . A second shaft 15 is attached to the front end of the gun butt holder 22 in a generally upright manner and is angled 10 degrees away from the leg 12 so as to allow the user to easily access the weapon 26 therein. The barrel 28 of the rifle 26 is inserted into a hook-like holder 30 which is attached to the upper end of the shaft 15 . The inside diameter of the hook 30 is lined with sponge which secures the barrel 28 therein so as to prevent abrasions to the barrel. The straps 16 , 18 and 20 is made of nylon. The present invention 10 is comprised of plastic.
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The present invention discloses an apparatus for holding a firearm onto the leg of a user comprising a pair of adjustable shafts being adjustable in length, which run longitudinally along the lower leg of the user having upper and lower straps which attach to the leg of the user. The lower portion of one shaft has a plastic holder for receiving the butt of the firearm and an upper arm for receiving a barrel of the firearm so that the firearm is angled away from the body of the user.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of my application Ser. No. 10/324,205, filed Dec. 19, 2002, claiming priority on my Provisional Patent Application No. 60/342,039, filed Dec. 26, 2001.
TECHNICAL FIELD
[0002] The present invention relates to a migratory fish diversion channel for a dam or a series of dams in a river. More particularly, it relates to the provision of a man made channel that substantially follows the original grade of the land along a bank of the river when the river was a free flowing river before the construction of the dams.
BACKGROUND OF THE INVENTION
[0003] The following are prior art patent documents that disclose the use of channels for routing migratory fish around a dam in a river. U.S. Pat. No. 3,772,891, granted Nov. 20, 1973, to John E. Raistakka; U.S. Pat. No. 3,938,340, granted Feb. 17, 1976, to Dalles I. Downs; U.S. Pat. No. 4,740,105, granted Apr. 26, 1988, to Jon R. Wollander; U.S Patent Pub. No. U.S. 2002/0187006 A1, published Dec. 12, 2002, naming Gordon Charles Burns II as the inventor; Japanese Patent Publication No. JP409250123 A, published Sep. 22, 1997, listing Kunitaka Sasaki as the inventor; Japanese Patent Publication No. JP410102463 A, published Apr. 21, 1998, naming Kenichi Watabe as the inventor; Japanese Patent Publication No. JP411315528 A, published Nov. 16, 1999, naming Kunitaka Sasaki as the inventor; Japanese Patent Publication No. JP 02000233194 A, published Aug. 29, 2000, naming Masahiro Kishimoto as the inventor; Japanese Patent Publication No. JP2003147754 A, published May 21, 2003, naming Tohoku Sekizai Block Ka as the assignee; and Japanese Patent Publication No. JP404200696 A, published Jul. 21, 1992, naming Takao Tawara as the inventor.
[0004] U.S. Pat. No. 3,772,891 discloses providing a fish conduit that extends from a region below a dam to a region above the dam. The conduit is shown in the nature of sections of pipe connected together to provide a tubular conduit. Published patent application U.S. 2002/0187006 A1 teaches using a man made artificial stream in place of the tubular conduit. The stream connects a region of the river below the dam with a region of the river above the dam. The artificial stream is in the nature of a meandering nature-like channel constructed of concrete, shotcreat or gunite that simulates a waterway bed condition. The other patents of the above identified group of patents relate for the most part to specific channel structures for the passage of fish around a dam in a river.
[0005] There is a need for a simple yet effective way of providing for upstream and downstream fish migration past a series of dams in a river while retaining the economic benefits of the dams. An object of the present invention is to supply this need.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The fish diversion system of the present invention is for use in a river that includes at least one dam, a river section below the dam, and a reservoir above the dam. The river section has a river bank and the reservoir has a reservoir bank. The invention is basically characterized by a fish diversion channel that extends from the river section below the dam, upstream past the dam to the reservoir, and then further upstream alongside of the reservoir. The fish diversion channel has inner and outer side walls and a bottom. The inner side wall extends upwardly from the bottom and has a top that is above the water level in the reservoir. The bottom substantially follows the grade of the ground below the channel. The inner and outer side walls and the bottom form a water passageway that substantially follows the natural grade of the reservoir bottom at the bottom of the channel. The water passageway communicates with the river section below the dam and extends upstream alongside the reservoir above the dam.
[0007] Preferably, the fish diversion system will be used with a river that includes a plurality of dams in series, including a lower dam and an upper dam. The river includes a river section below the lower dam and a river section above the upper dam. A reservoir is formed by each of the dams, ,each upstream of its dam. Each river section has a river bank and each reservoir has a reservoir bank. The fish diversion channel extends from the river section below the lower dam, upstream past each of the dams and alongside of each of the reservoirs, to the river section above the upper dam. The fish diversion channel has inner and outer side walls and a bottom. The inner side wall of the channel extends upwardly from the bottom of the channel and has a top that is above the water surface of each reservoir. The bottom of the channel substantially follows the natural grade of the ground. The inner and outer side walls and the bottom form a water passageway that substantially follows the natural grade of the river. This water passageway communicates with the river section below the lower dam and with a river section above the upper dam.
[0008] Dams include abutments at their ends that extend into the ground formations that are outwardly of the ends of the dam. In the vicinity of the abutment at its end of the dam, the fish diversion channel may be in the form of a tunnel opening that extends through the abutment.
[0009] According to an aspect of the invention, a variable area section may be provided in the fish diversion channel at the upper end of the reservoir for the upper dam. This variable area section is operable for controlling the flow or quantity of water that flows downstream into the fish diversion channel. In a typical embodiment, the variable area section may comprise a gate that is extendable and retractable horizontally for changing the cross sectional area of the channel. Or, it may comprise a gate that is extendable and retractable vertically, for changing the cross sectional area of the channel. Or, it may comprise both a horizontal gate and a vertical gate.
[0010] Other objects, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims, and from the principles that are embodied in these specific structures that are illustrated and described herein.
BRIEF DESCRIPTION OF THE SEVERAL FIGURES OF THE DRAWING
[0011] Like reference numerals referred to like parts throughout the several views of the drawing, and:
[0012] [0012]FIG. 1 is a top plan view of a river that includes a series of four dams;
[0013] [0013]FIG. 2 is a diagram showing the natural grade of the land and the region of the four dams and the reservoirs that are formed by the dams;
[0014] [0014]FIG. 3 is a cross sectional view of the river and a migratory fish bypass channel at the deep end of a reservoir behind one of the dams, such a view being taken substantially along line 3 - 3 of FIG. 2;
[0015] [0015]FIG. 4 is a cross sectional view of the river at the upper or shallow end of the reservoir, taken substantially along line 4 - 4 of FIG. 2; and
[0016] [0016]FIG. 5 is a cross sectional view of a section of the bypass panel that has been provided with gates for maintaining a substantially constant flow into the channel as the water level in the river/reservoir fluctuates.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The diversion channel of the present invention makes it easier for fish to locate and negotiate than the fish ladders currently being used at most dams. This is because the grade level of the water in the channel substantially follows the grade level of the land before the dams were constructed. As a result, the path to be traveled by the fish in the channel is much less steep than the path to be traveled in a fish ladder and there is a corresponding reduction in the velocity of the water flowing through the channel. The channel would appeal to downstream migrating baby fish (e.g., fingerlings) because it has the appearance of a natural stream. It is also beneficial to the fish as opposed to the slow moving reservoir behind each dam because in the reservoirs the water temperature is higher and the amount of oxygen is less than provided by the water in the channel.
[0018] According to the present invention, the channel is made to substantially follow the original grade of the river in which the dams were built. The side walls and bottom of the channel are made of concrete or some other durable material. The side wall adjacent the water has a top that is above the water surface at each location along the length of the river. The channel depth and width are sufficient to provide a bypass stream that is conducive to the movement and spawning of migratory fish. The bottom of the channel is preferably covered with natural rocks and gravels so as to simulate a natural stream bottom.
[0019] Referring to the drawing figures, which are not to scale, FIGS. 1 and 2 show, for example, the four dams that are on the Snake river 12 above where the river 12 connects with the Columbia river 10 . This is roughly a one hundred and fifty mile stretch of river that has been divided by the dams into a system of reservoirs that are separated by the dams. The bypass channel provided by the present innovation could be constructed around some or all of these dams and their associated reservoirs. In the example shown by FIGS. 1 and 2, “Ice Harbor” dam is designated 14 . “Lower Monumental” dam is designated 16 . “Little Goose” dam is designated 18 . “Lower Granite” dam is designated 20 . The water level in the four reservoirs is designated 22 , 24 , 26 , 28 . The water level in the bypass channel C is designated 30 . This channel C connects the river region 12 below the lower dam 14 with the river region 12 above the upper reservoir 28 . In FIG. 2, the concrete walls that bound the channel on the water side of the channel are designated 32 . FIGS. 1 and 2 show the bypass channel by passing all four of the dams, 14 , 16 , 18 , 20 . Alternatively, the bypass channel C could be constructed to move past only one, two or three of the dams and their associated reservoirs.
[0020] [0020]FIG. 3 is a cross sectional view taken substantially along line 3 - 3 of FIG. 2. This figure illustrates the cross sectional shape of the reservoir and the bypass channel C closely adjacent the dam 16 adjacent the lower end of reservoir 24 . FIG. 3 shows that in the vicinity of the dam 16 , the channel C is formed by an inner wall 34 , and outer wall 36 , a bottom 38 and a reinforcing member 40 . The reinforcing member 40 is necessary because the wall 34 is at its tallest where it needs the dam 16 at the lower end of the reservoir. The concrete structure 34 , 36 , 38 , 40 may be incorporated within an abutment 32 at the channel end of the dam 16 if such an abutment is deemed necessary and is employed. The abutment 32 may include wall 34 and extend over to the bank 42 , with the channel C being formed by a passageway that is formed in the abutment structure running in the direction of the river, alongside wall 34 . In some installations, inner and outer walls 34 , 36 may be employed and the structure 40 may be a series of diagonal struts 40 interconnecting portions of the walls 34 , 36 .
[0021] [0021]FIG. 3 shows that the water level 30 in the channel C is substantially below the water level 24 in the reservoir. The water level 24 in the reservoir is at a constant height and determined by the height of the dam, whereas the water level 30 in the channel slopes upwardly and downwardly as it follows the natural slope of the land. This is shown by FIG. 2. FIG. 3 shows natural rocks and gravel 44 provided on the channel bottom 38 so as to simulate the bottom of a natural stream. The size of the rocks can vary, between gravel size and boulder size, if desired.
[0022] [0022]FIG. 4 is a cross sectional view taken substantially along line 4 - 4 of FIG. 2. It presents a cross sectional view of the river adjacent the upper end of the reservoir 24 . FIG. 4 shows that at the upper end of the reservoir 24 , the water level 30 in the channel C is close in height to the water level in the reservoir 24 . At this end of the reservoir 24 , the height of the wall 34 is much lower than it is adjacent the dam 16 . At this location, it may not be necessary to employ a connecting structure 40 , so one is not illustrated. As shown by FIG. 2, each channel wall 34 varies in height from its lower end up to its upper end. At some location between the lower dam (e.g., 14 ) and the upper dam (e.g., 16 ), the need for a supporting or bracing structure 40 may disappear and above that location the supporting or bracing structure may be eliminated.
[0023] The shape of the lower portion of the channel C may be substantially constant throughout the length of the channel C. FIG. 4 shows an example minimum height of the 15 channel C. FIG. 3 shows an example maximum height of the channel C. As shown by FIG. 2, the water level 30 remains substantially constant throughout the length of the channel C. By way of an example, the depth of the water in the channel C may be approximately six to ten (6-10′) feet. This depth may be substantially constant throughout the full length of the channel C.
[0024] [0024]FIG. 5 is a cross sectional view taken substantially along line 5 - 5 of FIG. 2. It shows the shape of the channel C at the upper end of the upper reservoir 28 . In the region shown by FIG. 5, the channel C may be provided with a horizontal control gate 50 and a vertical control gate 52 . A pocket for receiving the horizontal gate 50 may be formed in the material 54 located laterally outwardly of the wall 36 . A pocket for the gate 52 may be formed in the material 56 below the channel bottom 38 . These pockets are designated 58 , 60 in FIG. 6. Hydraulic actuators 62 , 64 may be provided for extending and retracting the gates 50 , 52 . The gates 50 , 52 and their actuators 62 , 64 may be like or similar to the gates and actuators that are used in irrigation water passageways.
[0025] [0025]FIG. 5 for example shows a highwater height 28′ of the reservoir 28 and a low level height 28″ of the reservoir 28 . The gates 50 , 52 are used to regulate the amount of water entering into the channel 30 as the water level varies between the high and low levels 28′, 28″. The system shown by FIG. 5 is only one of a number of systems that could be used for regulating the water flow into the channel C. As well be evident, movement of the horizontal gate 50 to the right, as illustrated, will narrow the size of channel C. Movement of the vertical gate 52 upwardly will lower the depth of the water entering into the channel C. The opposite movement of the gates 50 , 52 will increase the cross sectional area opening permitting water flow into the channel C.
[0026] The use of the wall spaced inwardly of the water from the natural reservoir bank makes possible the construction of a fish diversion channel that allows upstream and downstream fish migration on a grade approximating that of a natural stream. As described above, and as illustrated in the drawing, the channel C uses the shoreline on one side of the reservoir and a wall made of a concrete or other suitable material that is spaced from the shoreline. The benefits of the resulting fish diversion channel C include retaining the existing dams for navigation, irrigation, recreation, hydropower and fish/wildlife maintenance, while providing for improved migrating fisheries. The channel provides for easy upstream migration by the fish when they are spawning, a natural downstream migration for smolts, considerable additional spawning grounds, swifter water flow in the channel to reduce heat absorption by the water in the channel and the fish that would occur if the fish and water had to pass through the warm water of the reservoirs, and eliminates the need for the smolts to go over the dams and suffer nitrogen poisoning, or go through the turbines and be destroyed. Additionally, the fish diversion channel system of the invention would save the cost of removing the dams, thus retaining the economic benefits of the dams. It would avoid resorting to the use of trucks to transport grain/lumber, making unnecessary the resulting fuel consumption, safety hazards, road erosion and air pollution. If the fish diversion channel is made of concrete or other durable material, it would last as long as the dams themselves. The water flow in the fish diversion channel can be directly controlled to facilitate optimal flow for fish unaffected by the remainder of the river as it flows through the dams. Currently, the fish get only the remaining water left over from the dams. Also avoided would be an estimated ten years of destruction of spawning habitats by silt flow if dams are removed.
[0027] Given the information that is set forth above, one could construct other embodiments of the present invention. The systems that have been described are all presented for purposes of illustration and not limitation. I am only to be limited to the wording of the claims which follow, and interpreted in accordance with the rules of patent claim interpretation, including use of the doctrine of equivalents.
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A bypass channel (C) for fish extends along line one side of a river, for the full length of a section of the river in which reservoirs ( 22, 24, 26, 28 ) have been created by dams ( 14, 16, 18, 20 ). The channel (C) follows the grade of the natural river. It includes an inner wall (34) that varies in height so that it is always higher than the water level in any of the reservoirs. It also includes an outer wall ( 36 ) and a bottom wall ( 38 ) which are formed on the natural terrain that borders the river and reservoirs. In at least its taller regions, the inner wall ( 38 ) may be braced by a diagonal member or a system of member ( 40 ). Water flow into the channel (C) maybe regulated by horizontal and/or vertical gates ( 50, 52 ) or some other structure for changing the cross sectional area of the channel (C).
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TECHNICAL FIELD
[0001] The present invention relates to a feed system for a continuous digester in which wood chips are cooked for the production of cellulose pulp according to the preamble to claim 1 .
PRIOR ART
[0002] In older conventional feed systems for continuous digesters, high-pressure pocket feeders have been used as sluice feeders for pressurisation and transport of a chips slurry to the top of the digester.
[0003] The Handbook of Pulp , (Herbert Sixta, 2006) discloses this type of feeding with high-pressure pocket feeders ( High Pressure Feeder ) on page 381. The big advantage with this type of feed is that the flow of ships does not need to pass through pumps, but is instead transferred hydraulically. At the same time it is possible to maintain a high pressure in the transfer circulation to and from the digester without losing pressure. The system has however demonstrated some disadvantages in that the high-pressure pocket feeder is subjected to wear and must be adjusted so that the leakage flow from the high-pressure circulation to the low-pressure circulation is minimized. Another disadvantage is that during transfer, the temperature must be kept low so that bangs related to steam implosions do not occur in the transfer.
[0004] As early as 1957, U.S. Pat. No. 2,803,540 disclosed a feed system for a continuous chip digester where the chips are pumped from an impregnation vessel to a digester in which the chips are cooked in a steam atmosphere. Here, a part of the cooking liquor is charged to the pump to obtain a pumpable consistency of 10%. However, this digester was designed for small scale production of 150-300 tons pulp per day (see col 7, r. 35).
[0005] Also, U.S. Pat. No. 2,876,098 from 1959 discloses a feed system for a continuous chip digester without a high-pressure pocket feeder. Here the chips are suspended in a mixer before they are pumped with a pump to the top of the digester. The pump arrangement is provided under the digester and here the pump shaft is also fitted with a turbine in which pressurised black liquor is depressurised to reduce the required pump energy.
[0006] U.S. Pat. No. 3,303,088 from 1967 also discloses a feed system for a continuous chip digester without a high-pressure pocket feeder, where the wood chips are first steamed in a steaming vessel, followed by suspension of the chips in a vessel, whereafter the chips suspension is pumped to the top of the digester.
[0007] U.S. Pat. No. 3,586,600 from 1971 discloses another feed system for a continuous digester mainly designed for finer wood material. Here, a high-pressure pocket feeder not used either, and the wood material is fed with a pump 26 via an upstream impregnation vessel to the top of the digester.
[0008] Similar pumping of finer wood material to the top of a continuous digester is also disclosed in EP157279.
[0009] Typical for these embodiments of digester systems from the late 50's to the beginning of the 70's is that these were designed for small digester houses with a limited capacity of about 100-300 tons pulp per day.
[0010] U.S. Pat. No. 5,744,004 shows a variation of feeding wood chips into a digester where the chips mixture is fed into the digester via a series of pumps. Here, so called DISCFLO™ pumps are used. A disadvantage with this system is that this type of pump typically has a very low pump efficiency.
[0011] The previously mentioned Handbook of Pulp also discloses on page 382 an alternative pump feed of chips mixtures called TurboFeed™. Here three pumps are used in series to feed the chips mixture to the digester. This type of feed has been patented in U.S. Pat. No. 5,753,075, U.S. Pat. No. 6,106,668, U.S. Pat. No. 6,325,890, U.S. Pat. No. 6,336,993 and U.S. Pat. No. 6,551,462; however in many cases, U.S. Pat. No. 3,303,088 for example, has not been taken into consideration.
[0012] U.S. Pat. No. 5,753,075 relates to pumping from a steaming vessel to a processing vessel. U.S. Pat. No. 6,106,668 relates specifically to the addition of AQ/PS during pumping.
[0013] U.S. Pat. No. 6,325,890 relates to at least two pumps in series and the arrangement of these pumps at ground level.
[0014] U.S. Pat. No. 6,336,993 relates to a detail solution where chemicals are added to dissolve metals from the wood chips and then drawing off liquor after each pump to reduce the metal content of the pumped chips.
[0015] U.S. Pat. No. 6,551,462 essentially relates to the same system already disclosed in U.S. Pat. No. 3,303,088.
[0016] A big disadvantage with the systems with multiple pumps in series is limited accessibility. If one pump breaks down, the whole digester system stops. With 3 pumps in series and a normal accessibility for each pump of 0.95, the total systems accessibility is just 0.86 (0.95*0.95*0.95=0.86).
[0017] Today's modern continuous digesters with capacities over 4000 tons pulp per day use digesters that are 50-75 meters high, where a gauge pressure of 3-8 bar is established in the top of the digester in the case of a steam phase digester, or 5-20 bar in the case of a hydraulic digester. The continuous digester systems are designed to, during the main part of operation, typically well over 80-95% of operation, run at nominal production, which makes it necessary, in regard to operational costs, for the pumps to be optimized for nominal production.
[0018] A typical digester system with a capacity of about 3000 tons with a feed system with the so called “TurboFeed™” technology requires about 800 kW of pumping power. It is obvious that these systems must have pumps that run at an optimized efficiency close to their nominal capacity. Such a feed system requires 19,200 kWh (800*24) per 24 hours, and at a price of 50 Euro per MWh, the operational cost comes to 960 Euro per 24 hours or 336,000 Euro per year.
[0019] The systems must also be able to be operable within 50-110% of nominal production which places great demands on the feed system.
[0020] This means that a system supplier must offer pumps that are large enough to handle 4000 tons and that may also be operated within a 2000-4400 ton interval. Such a pump operated at 50% of its capacity is far from optimised, but it is necessary to at least temporarily be able to operate the pump at limited capacity in case of temporary capacity problems, for example further down the fibre line.
[0021] If this system supplier offers digester systems that can handle nominal capacities of 500-5000 tons, then pumps must be designed in a number of different pump sizes so that each individual installation can offer, from a power consumption and energy perspective, optimised transfer at nominal production. This makes the pumps very expensive, as normally a very limited series of pumps are manufactured in each size. To be able to meet demands of reasonably short delivery times, the system supplier must stock pumps in all pump sizes, which is very expensive.
[0022] The digester feed should also be able to guarantee optimal feeding to the top of the digester even if the flow in the transfer line is reduced to 50% of nominal flow.
[0023] This is difficult, because the flow rate in the transfer lines should be maintained above a critical level, as well-steamed chips have a tendency to sink against the direction of the transfer flow if the speed becomes too low.
[0024] A corrective measure that can be used at low rates, is to increase the dilution before pumping so that a lower chips concentration is established. This is however not energy efficient as it forces the feed systems to pump unnecessarily high volumes of fluid, which increases the pump energy consumption per produced unit of pulp.
[0025] Each pump has a construction point (Best Efficiency Point/“BEP”) at which the pump is intended to work. At this “BEP”, shock induced loss and frictional loss are, in the case of centrifugal pumps, at their lowest which in turn leads to that the pumps efficiency is highest at this point.
Aim of the Invention
[0026] A first aim of the present invention is to provide an improved feed system for wood chips wherein optimal transfer can be achieved within a broader interval around the digesters design capacity.
[0027] Other aims of the present invention are;
improved efficiency of the feed system; improved accessibility; lower operational costs per pumped unit of chips; constant chip concentration during pumping regardless of production level; a limited range of pump sizes that can cover a broad span of the digesters production capacity; simplified maintenance; lower installation costs compared to feed systems with high-pressure pocket feeders or multiple pumps in series;
The above mentioned aims may be achieved with a feed system according to the characterizing part of claim 1 .
FIGURES
[0035] FIG. 1 shows a first system solution for feed systems for digesters with a top separator;
[0036] FIG. 2 shows a second system solution for feed systems for digesters without a top separator;
[0037] FIGS. 3-6 show different ways of attaching pumps to an outlet in a pre-treatment vessel;
[0038] FIG. 7 shows the feed system's connection to the top of a digester without a top separator; and
[0039] FIG. 8 shows a top view of FIG. 7 ;
[0040] FIG. 9 shows a third system solution for feed systems for digesters without a top separator;
[0041] FIG. 10 shows a fourth system solution for feed systems for digesters with a top separator, and
[0042] FIG. 11 shows how the transfer lines from each pump in the systems in FIGS. 9 and 10 may be combined to form one single transfer line.
[0043] FIG. 12 shows a second alternative of how the transfer lines from each pump may be combined to form one single transfer line, and
[0044] FIG. 13 shows a third alternative of how the transfer lines from each pump may be combined to form one single transfer line.
DETAILED DESCRIPTION OF THE INVENTION
[0045] In the following detailed description, the phrase “feed system for a continuous digester” will be used. “Feed system” herein means a system that feeds wood chips from a low-pressure chips processing system, typically with a gauge pressure under 2 bar and normally atmospheric, to a digester where the chips are under high pressure, typically between 3-8 bar in the case of a steam phase digester or 5-20 bar in the case of a hydraulic digester.
[0046] The term “continuous digester” herein means either a steam phase digester or a hydraulic digester even though the preferred embodiments are exemplified with steam phase digesters.
[0047] A basic concept is that a feed system comprises at least 2 pumps in parallel, but preferably even 3, 4 or 5 pumps in parallel. It has been shown that a single pump can feed a chips suspension to a pressurised digester, and it is therefore possible to exclude conventional high-pressure pocket feeders or complicated feed systems with 2-4 pumps in series.
[0048] The pumps are arranged in a conventional way on the foundation at ground level to facilitate service.
[0049] With the above outlined solution it is possible to provide feed systems for digester production capacities from 750 to 6000 tons pulp per day, with only a few pump sizes. This is very important, as these pumps for feeding wood chips at relatively high concentration are very specific in regard to their applications, and pumps that are able to handle production capacities of 4000-6000 tons pulp per day are very large and only manufactured in very limited series of a few pumps per year. The cost for these pumps therefore becomes a crucial factor for a digester system.
[0050] The table below shows an example of how it is possible to cover a production interval of 750-6000 tons with only two pump sizes optimised for 750 and 1500 tons pulp, respectively, per day;
[0000]
PUMP PROGRAM
Nominal Production
750
1500
Capacity (ton per day)
pump
pump
750
1 unit
1500
2 units
2250
1 unit
1 unit
(2250 alt)
(3 units*)
—
3000
—
2 units
(3000 alt)
(4 units*)
3750
1 unit
2 units
4500
—
3 units
(4500 alt)
(2 units*)
(2 units*)
5250
1 unit
3 units
6000
4 units
(X unit* = 1: st alternative)
[0051] This table clearly shows how it is possible, with the concept according to the present invention, to cover production capacities between 1500-6000 tons with only 2 optimised pump sizes while using a single pump installation in smaller digester systems with a capacity of 750 tons. Continuous digesters with a capacity of 750 tons are seldom used for new installations today, because batch digester systems are often more competitive for these capacities. A certain after market may exist for older digester systems with a low capacity where expensive feed systems with high-pressure pocket feeders are still used.
First Embodiment
[0052] FIG. 1 shows an embodiment of the feed system with at least 2 pumps in parallel. The chips are fed with a conveyor belt 1 to a chips buffer 2 arranged on top of an atmospheric treatment vessel 3 . In this vessel, a lowest liquid level, LIQ LEV , is established by adding an alkali impregnation liquid, preferably cooking liquor (black liquor) that has been drawn off in a strainer screen SC 2 in a subsequent digester 6 , and possibly adding white liquor and/or another alkali filtrate.
[0053] The chips are fed with normal control of the chip level CH LEV which is established above the liquid level LIQ LEV .
[0054] The remaining alkali content in the black liquor is typically between 8-20 g/l. The amount of black liquor and other alkali liquids that are added to the treatment vessel 3 is regulated with a level transmitter 20 that controls at least one of the flow valves in lines 40 / 41 . With this alkali impregnation liquor the wood acidity in the chips may be neutralised and impregnated with sulphide rich (HS − ) fluid. Spent impregnation liquor, with a remaining alkali content of about 2-5 g/l, preferably 5-8 g/l, is drawn off from the treatment vessel 3 via the withdrawal strainer SC 3 and sent to recovery REC. If necessary, white liquor WL may also be added to the vessel 3 , for example as shown in the figure, to line 41 . The actual remaining alkali content depends on the type of wood used, hardwood or softwood, and which alkali profile that is to be established in the digester.
[0055] In the case where a raw wood material that is easy to impregnate and neutralise is used, for example raw wood material such as pin chips or wood chips with very thin dimensions and a quick impregnation time, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel. Required retention time in the vessel is determined by the time it takes for the wood to become so well impregnated that it sinks in a free cooking liquor.
[0056] After the chips have been processed in vessel 3 they are fed out from the bottom of the vessel where also a conventional bottom scraper 4 is arranged, driven by a motor M 1 .
[0057] According to the invention, the chips are fed to the digester via at least 2 pumps 12 a , 12 b in parallel, and these pumps are connected to a bucket formed outlet 10 in the bottom of the vessel. The bucket formed outlet 10 has an upper inlet, a cylindrical mantle surface, and a bottom. The pumps are connected to the cylindrical mantle surface.
[0058] To facilitate pumping of the chips mixture, the chips are suspended in a vessel 3 to create a chips suspension, in which vessel is arranged a fluid supply via lines 40 / 41 , controlled by a level transmitter 20 which establishes a liquid level LIQ LEV in the vessel, and above the pump level by at least 10 meters, and preferably at least 15 meters and even more preferably at least 20 meters. Hereby a high static pressure is established in the inlet to pumps 12 a and 12 b so that one single pump can pressurise and transfer the chips suspension to the top of the digester without cavitation of the pump. The top of the digester is typically arranged at least 50 meters above the level of the pump, usually 60-75 meters above the level of the pump while a pressure of 5-10 bar is established in the top of the digester.
[0059] To further facilitate the feeding to the pumps, a stirrer 11 is arranged in the bucket formed outlet. The stirrer 11 is preferably arranged on the same shaft as the bottom scraper and driven by the motor M 1 . The stirrer has at least 2 scraping arms that sweep over the pump outlets arranged in the bucket formed outlet's mantle surface. Preferably a dilution is arranged in the bucket formed outlet, which may be accomplished by dilution outlets (not shown) connected to the upper edge of the mantle surface.
[0060] FIGS. 3-6 show how a number of pumps 12 a - 12 d may be connected to the outlet's cylindrical mantle surface and how the stirrer 11 may be fitted with up to 4 scraping arms. The pumps may preferably be arranged symmetrically around the outlets cylindrical mantle surface with a distribution in the horizontal plane of 90° between each outlet if there are 4 pump connections (120° if there are 3 pump connections and 180° if there are 2 pump connections). This way it is possible to avoid an uneven distribution of the load on the bottom of the vessel and its foundation. In practice, shut-off valves (not shown) are also arranged between the outlet's 10 mantle surface and the pump inlet and a valve directly after the pump to make it possible to shut off the flow through one pump if this pump is to be replaced during continued operation of the remaining pumps.
[0061] In FIG. 1 the chips are fed by pumps 12 a , 12 b via transfer lines 13 a , 13 b (only two shown in FIG. 1 ) to the top of the digester 6 . FIG. 1 shows a conventional top separator 51 arranged in the top of the digester. The transfer lines 13 a , 13 b , preferably 2, both open into the bottom of the top separator, where, driven by motor M 3 , a feeding screw 52 drives the chips slurry up under a dewatering process against the top separators withdrawal strainer SC 1 . Drained chips will then be fed out from the upper outlet of the separator in a conventional way and fall down into the digester. In the case a hydraulic digester is used, the top separator is turned up-side down, and feeds the chips down into the digester.
[0062] The drained liquid from the top separator 51 is led through a line 40 back to the processing vessel 3 , and may preferably be added to the bottom of the processing vessel, to there facilitate feeding out under dilution.
[0063] Alternatively, line 40 may be connected to the position for the outlet of line 41 in the processing vessel 3 and line 41 may be connected to the position for the outlet of line 40 in the processing vessel 3 , according to the concept CrossCirc™. In a variation, the flow of line 40 and 41 may be mixed at the intersection of lines 40 and 41 in FIG. 1 .
[0064] The digester 6 may be fitted with a number of digester circulations and the addition of white liquor to the top of the digester or to the digester's supply flows (not shown). The figure shows a withdrawal of cooking liquor via strainer SC 2 . The cooking liquor drawn off from strainer SC 2 is known as black liquor and may have a somewhat higher content of remaining alkali than black liquor that is normally sent directly to recovery and normally drawn off further down in the digester. The cooked chips P are then fed out from the bottom of the digester with the help of a conventional bottom scraper 7 and the cooking pressure.
Second Embodiment
[0065] FIG. 2 shows an alternative embodiment which does not include a top separator. Instead the transfer lines 13 a , 13 b (only two are shown in FIG. 1 ) open directly into the top of the digester. Excess liquid is then drawn off with a digester strainer SC 1 arranged in the digester wall. FIGS. 7 and 8 show this in more detail. The remaining parts of this embodiment correspond to the digester system shown in FIG. 1 .
[0066] FIG. 8 shows how 4 transfer lines 13 a , 13 b , 13 c and 13 d may open directly into the top of the digester. These outlets may preferably be arranged symmetrically in the top of the digester with a distribution in the horizontal plane of 90° between each outlet if there are 4 outlets (120° if there are 3 outlets and 180° if there are 2 outlets). The outlets are suitably arranged at a distance of 60-80% of the digester radius. FIG. 7 shows how the transfer lines 13 a , 13 b and 13 c open directly down into the top of the digester and thereby distribute the chips over the cross section of the digester. In this case a steam phase digester is shown where steam ST and/or pressurised air P AIR is added to the top of the digester, in which a chips level CH LEV is established above the liquid level LIQ LEV in the top of the digester. Excess liquid is drawn off with a strainer SC 2 and collected in a withdrawal space 51 before being led back via line 41 . An advantage with the second embodiment, but also with the first embodiment, is that each pump may closed independently while the remaining pumps may continue pumping at optimal efficiency and without requiring modification of the feed system itself.
Third Embodiment
[0067] FIG. 9 shows an alternative embodiment for the feed system to a continuous digester without a top separator where each pump 12 a , 12 b pumps the chips suspension through a first section 13 a , 13 b of a transfer line to the top of the digester, and the first sections of the transfer lines from at least 2 pumps are combined at a merging point 16 to form a combined second section 13 ab of the transfer line before this second section is led towards the top of the digester. To maintain a constant flow rate, a supply line 15 is also connected to the merging point 16 . In this embodiment black liquor is taken from line 41 and may be pressurised with a pump 14 . However, because the black liquor has already reached a full digester pressure, the need to pressurise the liquor is limited. All other characterizing parts of the system correspond to the system shown in FIG. 2 .
Fourth Embodiment
[0068] FIG. 10 shows an alternative embodiment for the feed system to a continuous digester with a top separator where each pump 12 a , 12 b pumps the chips suspension through a first section 13 a , 13 b of a transfer line to the top of the digester, and the first sections of the transfer lines from at least 2 pumps are combined at a merging point 16 to form a combined second section 13 ab of the transfer line before this second section is led towards the top of the digester. To maintain a constant flow rate, a supply line 15 is also connected to the merging point 16 . In this embodiment black liquor is taken from line 40 and may be pressurised with a pump 14 . However, because the black liquor has already reached a full digester pressure, the need to pressurise the liquor is limited. All other characterizing parts of the system correspond to the system shown in FIG. 1 .
[0069] FIG. 11 shows an example of how supply lines 15 a , 15 b that are used in both the third and the fourth embodiment may be connected to merging points 16 ′ in the case 4 pumps 12 a - 12 d are used. An advantage with this supply arrangement is that it is possible to guarantee optimal speed in the combined flow in the second section 13 ac / 13 bd and in the combined flow in the final third section 13 abcd of the transfer line.
[0070] It is critical that the rate of the flow up to the digester is well over 1.5-2 m/s so that the chips in the flow do not sink down towards the feed flow and cause plugging of the transfer line. The flow in the transfer line should suitably be maintained between 4-7 m/s to make sure that the chips are transferred to the top of the digester.
[0071] If, for example, pump 12 a would be shut down due to repair or a desired capacity reduction, the flow in addition line 15 a may be increased so that the flow rate in the second section 13 ac is maintained.
[0072] In these combined line systems for transferring chips suspensions it is advantageous that the lines after the merging points 16 , 16 ′, 16 ″ have a flow cross section that is equal to or greater than the sum of the incoming lines, to avoid pressure loss in the transfer lines. Suitable equations for flow areas A may be:
[0000] A 13bd ≧( A 13d +A 13b ), and
[0000] A 13abcd ≧( A 13bd +A 13ac ).
[0073] In a transfer line where the first section has a diameter of for example 100 mm and an established flow rate of 5 m/s, a flow rate of 4.4 m/s is established if a second section that combines 2 lines with diameter 100 mm has a diameter of 150 mm. With a subsequent combination of 2 such lines with a diameter of 150 mm to a third section with a diameter of 250 mm, a flow rate of 3.18 m/s may be established. All these flow rates have a margin towards the critical lowest flow rate.
[0074] The supply lines 15 a , 15 b may also have connections directly after each pump outlet, so that the line between pump and merging point is kept flushed during the time that the pump is shut down or operated at a reduced capacity. The addition of extra fluid may also be combined with a further dilution of the chips suspension before the pumps, for example on the suction side of the pumps or in the bottom of vessel 3 .
[0075] FIG. 12 shows a cross-sectional view of a second embodiment of how lines 13 a - 13 d from the pumps may be combined to form one single transfer line 13 abcd . Here, the supply line 15 for dilution liquid provides a vertical part of the transfer line towards the top of the digester, and each line 13 a , 13 b , 13 c , 13 d from each pump is connected successively, one by one, to this vertical part of the transfer line at different heights. At each supply position, the chip flow is added in a conical part of a diameter increase in the transfer line. As is indicated by the dashed alternatives 13 b ALT / 13 d ALT , the connections from the pumps may instead be shifted from side to side on the transfer line.
[0076] FIG. 13 shows a cross-sectional view of a third embodiment of how lines 13 a - 13 d from the pumps may be combined to form one single transfer line 13 abcd . Here, the supply line 15 for dilution liquid provides a vertical part of the transfer line towards the top of the digester, and each line 13 a , 13 b , 13 c , 13 d from each pump is connected at the same height to this vertical part of the transfer line. Preferably the supply position for the chip flow is arranged in a conical part of a diameter increase in the transfer line and each connected line is oriented upwards and inclined at an angle in relation to the vertical orientation in the interval 20-70 degrees. The Figure shows only the connections 13 a , 13 b , 13 c , as connection 13 d is in the part that is cut away in this view.
[0077] The invention is not limited to the above mentioned embodiments. More variations are possible within the scope of the following claims. In the embodiments shown in FIGS. 2 and 9 , in some applications the strainer SC 1 and the return line 40 may for example be omitted, preferable for cooking of wood material with a higher bulk density, such as hardwood (HW), that for a corresponding production volume require less liquid during transfer.
[0078] In the case where a raw wood material that is easy to impregnate and neutralise is used, for example raw wood material such as pin chips or wood chips with very thin dimensions and a quick impregnation time, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel.
[0079] If the chips fed into the vessel 3 are already well steamed, the liquid level LIQ LEV may be established above a chips level CH LEV .
[0080] In the embodiments shown, an alkali pre-treatment was used in vessel 3 , but it is also possible to use a process where this pre-treatment comprises acid pre-hydrolysis.
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The feed system is for a continuous digester where at least two pumps are arranged in parallel at the bottom of a pre-treatment vessel and a stirrer is provided in direct connection to inlets to pumps. The system makes it possible to provide a feed system with an improved accessibility and operational reliability, and to operate the main part of the pumps at optimal efficiency even if the production capacity is reduced.
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FIELD OF THE INVENTION
The present invention relates generally to a device for slowing down printed products and more particularly to a device for decelerating signatures in a folding machine through a smooth velocity profile.
BACKGROUND OF THE INVENTION
Fan wheels are commonly used devices for slowing down signatures in a folding machine. Fan wheels comprise a plurality of fan wheel discs defined by a plurality of outwardly projecting curve-shaped fan blades. Fan wheel pockets formed by adjacent blades receive signatures exiting a folding device. The curve shape and jagged surface of the fan blades slow the forward movement of the signatures being deposited in the fan pockets to a complete stop. Once a given fan pocket receiving a signature has turned through approximately 90° the signature is deposited on a delivery system.
A drawback of devices of this nature is that because the signatures enter the fan wheel pockets at such high velocities they are thrust tumultuously against the blades of the fan wheel causing the signatures to tear and otherwise become damaged. Another drawback of these devices is that it is not possible to precisely aim the products towards the bottoms of the fan wheel pockets.
The reason for this is that as the signatures come off belts leading to the fan wheel, a number of factors come into play, such as the paper caliper, the number of pages in the signature, the nature of the paper and even the amount of ink thereon, which will all affect the motion of the signature so that, dependent on the cumulative effect of such factors the signature may land neatly on the bottom of the fan wheel pocket or may recoil backwards or catch on the edge of a fan wheel blade. Once a signature is irregularly positioned on the fan wheel, it will be deposited onto the delivery belt irregularly as well and the product stream thereon is likely to contain laterally displaced, unevenly spaced or skewed signatures. This is especially true where large speed reductions, e.g., (5:1) are required.
U.S. Pat. No. 4,629,175 discloses an apparatus intended to overcome some of these drawbacks. The apparatus comprises a number of rows of grippers rotating between a transfer or supply device and a delivery system. The grippers are slowed down by an acceleration/deceleration drive running in the direction of motion from the transport or supply device to the delivery system from approximately the supply speed to approximately the speed of the delivery system and are able to be accelerated up to the speed they were moving at before such deceleration in the following section of their motion. The grippers are mounted to a cylindrical drum rotating at a constant speed, and the rows of grippers decelerated and accelerated by the deceleration/acceleration drive are turned at a speed equal to that of the drum and are mounted so that they may be shifted in relation to the outer face of the drum.
However, a drawback with this device is that the transfer of the signature from the supply device to the deceleration drum can cause distortion misalignment and/or tearing of the signature. Because this transfer is achieved by positioning the deceleration drum so that the gripper rotates into a position in front of the leading edge of the signature being delivered by the supply device, the velocity of the signature being controlled by the supply device must be greater than the tangential velocity of the gripper on the deceleration drum. This causes the signature to gain on the gripper until it has entered the throat of the gripper a desired distance. The gripper then closes and the velocity of the leading edge of the product abruptly changes to match the velocity of the gripper. If the trailing edge of the signature is in the control of the supply device at this time, then distortion of the signature will occur and possible tearing. A further drawback of this device is that it is not capable of achieving high speed reduction ratios as are now required to accommodate today's new high speed printing presses. This device is designed for speed reduction ratios of approximately 3:1. Speed reduction ratios of 5:1 are now being demanded.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a device for continuously handling a signature as it exits a folding device in a printing press and is transported to a delivery system for further processing.
It is another object of the present invention to provide a device for decelerating consecutive signatures along the same velocity curve.
It is a further object of the present invention to provide a device for delivering consecutive signatures from a folding device to a delivery system in an orderly fashion with minimal distortion, misalignment or damage to the products.
It is still another object of the present invention to provide a device for delivering consecutive signatures from a folding device to a delivery system in a shingled format where the pitch between consecutive signatures is precisely maintained.
The present invention provides a device for slowing down signatures being transported in a folding machine, comprising: means for positively gripping a leading edge of a signature exiting a transporting device in the folding machine traveling at a high velocity; and a deceleration drum for slowing down the signature through a smooth velocity profile, the deceleration drum having at least one pivot arm pivotally mounted on a pivot disc rotating about a first axis, the at least one pivot arm being connected to a control disc by a control link, the control disc rotating about a second axis parallel to, and offset from, the first axis, the gripping means being attached to an outward end of the at least one pivot arm. The gripping means preferably grips the leading edge of the signature as it exits the transporting device while the trailing edge is still being controlled by the transporting device.
The transporting device may be a cutting cylinder, folding cylinder, tape conveying system or other delivery system. The gripping means may be a gripper head or preferably a rotary gripper defined by a set of oppositely rotating upper and lower rollers which receive the leading edge of the signature exiting the transporting device at a nip formed between the upper and lower rollers. The rotary gripper prevents abrupt changes in the velocity of the signature as it is transferred from the transporting device to the slow down device, and hence minimizes distortion, misalignment and possible tearing of the signature during the slow down process. The deceleration drum may alternatively comprise a cam and linkage system in place of the pivot arm/pivot disc and control link/control disc mechanism.
An advantage of the present invention is that since the deceleration device continuously handles the signatures until they are ready for deposit on the delivery system, the product stream is unlikely to contain laterally displaced, unevenly spaced or skewed signatures.
Another advantage of the present invention is that since the transporting device does not use friction to slow down the signatures they are less likely to be damaged.
A further advantage of the present invention is that since consecutive signatures follow the same velocity curve the pitch never varies.
A still further advantage of the present invention is that it can obtain speed reduction ratios on the order of 5:1.
Other objects, characteristics and advantages of the present invention will become apparent in view of the detailed description along with the accompanying drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of one embodiment of a deceleration drum for slowing down signatures in a folding machine according to the present invention.
FIG. 2 is a schematic diagram of the deceleration drum shown in FIG. 1 showing the path of a point D where a control link attaches to a control disc as it moves relative to a point C where a pivot arm attaches to a pivot disc.
FIG. 3 is a geometric representation of the pivot arm/control link pair shown in FIGS. 1 and 2 illustrated as a stationary four bar linkage.
FIG. 4 is a graph of the angular velocity (in rad/sec) of the pivot arm as a function of the position (in degrees) of the pivot disc shown in FIGS. 1 and 2.
FIG. 5 is a graph of the angular velocity (in rad/sec) of the pivot disc as a function of the position (in degrees) of the control disc shown in FIGS. 1 and 2.
FIG. 6 is a graph of the tangential velocity (in ft/min) of the pivot arm as a function of the position (in degrees) of the deceleration drum shown in FIGS. 1 and 2.
FIG. 7 is a graph of the velocity (in ft/min) of a signature as a function of the position (in degrees) of the deceleration drum shown in FIGS. 1 and 2.
FIG. 8 is a schematic diagram showing a signature being gripped by a gripper head according to the present invention as the signature exists a tape conveyor system.
FIG. 9 is a schematic diagram of another embodiment of a deceleration drum and a rotary gripper system according to the present invention.
FIG. 10 is a schematic diagram of the deceleration drum/rotary gripper system shown in FIG. 9 illustrating delivery of the signatures in a single stack mode.
FIG. 11 is a schematic diagram of the deceleration drum/rotary gripper system shown in FIG. 9 illustrating delivery of the signatures in a shingled format.
FIG. 12 is a schematic diagram of another embodiment of a deceleration drum/rotary gripper system according to the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1 a deceleration drum according to the present invention for slowing down signatures in a folding machine is shown generally by reference number 10. The drum 10 comprises a plurality of pivot arms 12 which are connected to a rotating pivot disc 14 and allowed to pivot independently of each other. The connection points of the pivot arms 12 to the pivot disc 14 form a base circle concentric about the center of the pivot disc (point A). A control link 16 is connected to each pivot arm 12 at a point radially outward from the pivot point of the pivot arm. The opposite end of each of the control links 16 is connected to a rotating control disc 18. The connection points of the control links 16 to the control disc 18 form a base circle concentric about the center of the control disc (point B).
The pivot disc 14 and the control disc 18 rotate about their own centers at the same speed and in the same direction. The centers of the pivot disc 14 and the control disc 18 are fixed and offset from each other, by a distance d, that is the distance between points A and B, as shown in FIG. 1. The greater the offset of the centers, the larger the speed reduction of the pivot arms 12.
As the two discs 14, 18 rotate, the point at which the control link 16 attaches to the control disc 18 (point D) moves relative to the point at which the pivot arm 12 attaches to the pivot disc 14 (point C). The path of point D relative to point C is a circle c whose radius is equal to the offset distance d between the center of the pivot disc 14 and the center of the control disc 18, as shown in FIG. 2. This circular path exists for each pivot arm 12/control link 16 pair. Therefore, there exist a number of parallel circles equal to the number of pivot arm 12/control link 16 pairs. These parallel circles are positioned equidistant on a base circle about the center of pivot disc 14 and at a radius that is a function of the control link 16 length and control disc 18 size.
The deceleration drum 10 accepts signatures directly from a cutting cylinder, tape system or other transporting device at high speeds. The signatures are positively gripped and decelerated through a smooth velocity profile. Each signature is shingled and delivered from the drum 10 at a slow speed. The exact pitch of each shingled signature is a function of the pitch of the signature entering the drum 10 and the speed reduction ratio of the drum. To obtain optimum registration and control of the delivered signature product, a positive, gripped to gripper, transfer to a single copy gripper conveyor can be used. Performance of belt delivery, stack or log making, or other conventional systems will be improved due to the improved quality of the product registration delivered from the deceleration drum 10.
To achieve a desired velocity profile, the pivot arm 12/control link 16 geometry can be modeled as a stationary four bar linkage, as shown in FIG. 3. First, the pivot arm's 12 angular velocity relative to the position of the pivot disc 14 is analyzed using the four bar linkage model. A graph of this velocity profile is shown in FIG. 4. Once this velocity is determined, the tangential velocity of the end of the pivot arm 12 due to the rotation of the pivot disc 14 can be easily calculated. Next, the tangential velocity of the pivot arm 12 due to the angular rotation of the pivot disc 14 about the control disc 18 is calculated. A graph of the angular velocity of the pivot disc 14 about the control disc 18 is shown in FIG. 5. The two tangential velocities are then superimposed and the result of the superposition is the true tangential velocity of the pivot arm 12. A graph of this composite velocity is shown in FIG. 6. The geometry is preferably set so that the maximum tangential velocity of the pivot arm 12 is essentially matched to the signature velocity entering the deceleration drum 10 and the minimum tangential velocity of the pivot arm is essentially matched to the velocity of the delivery system receiving signatures from the drum. FIG. 7 shows a typical signature velocity profile according to the present invention.
Signatures 20 exiting a tape conveyor system 22 are gripped by a gripper head 24 attached at the outward end of each pivot arm 12, as shown in FIG. 8. The gripper head 24 grips the signature 20 as it enters the deceleration drum 10. The gripper head 24 is brought in to position to grip the leading edge of an incoming signature 20 and then begins to decelerate the signature. A cam (not shown) is used to control the timing of the gripper system. The system is preferably timed so that the leading edge of the incoming signature 20 is gripped by the gripper head 24 before the trailing edge of the signature is released by the tape conveyor system 22.
As the signature 20 decelerates in the drum 10, its pitch relative to an adjacent signature decreases until an overlapping shingle is induced. The shape of the gripper head 24 is wedged in the direction of travel so that the gripper head will push a previous signature outward and allow for the initiation of a shingle, as shown in FIG. 8. The pitch of adjacent signatures in the deceleration drum 10 decreases until the signatures reach the delivery velocity when they are then released. The signature 20 is then taken away from the drum 10 by a delivery system (not shown).
In an alternate embodiment of the present invention, a rotary gripper 26 defined by a set of oppositely rotating upper and lower rollers 28, 30 is used to control the signature 20 on a deceleration drum 10A in place of the gripper head 20, as shown in FIG. 9. A nip 32 between the upper and lower rollers 28, 30 is the grip point for an incoming signature. The rotation of the upper and lower rollers 28, 30 about their respective axes is controlled by a cam or linkage system. The tangential velocity of the surface of the upper and lower rollers 28, 30 as they rotate about their respective axes is superimposed upon the tangential velocity of the nip 32 about the center of the decelerating drum 10A. The result of this superposition is a velocity that is essentially equal to the velocity of the signature 20 exiting the tape conveyor 22. This velocity match allows for the leading edge of the signature 20 to be controlled by the set of upper and lower rollers 28, 30 at the same time as the trailing edge of the signature is controlled by the tape conveyor system 22 without any distortion of the signature.
The nip 32 is positioned in the path of the signature just as the gripper head 24 is positioned. The rotary gripper 26 has the advantage of controlling the signature 20 from the instant that the leading edge of the signature 20 reaches the nip point 32. There is no need to wait for the signature 20 to enter a gripper throat defined by an opening between the oppositely rotary upper and lower rollers 28, 30 of the rotary gripper 26 before the deceleration drum 10A takes control of the signature. The leading edge of the signature 20 is driven into the in-running nip 32 the desired distance before the rotation of the upper and lower rollers 28, 30 about their respective axes stops. The upper and lower rollers 28, 30 follow a fixed velocity curve so that the signature 20 decelerates smoothly from its velocity exiting the tape system 22 to the velocity of the deceleration drum 10A.
To release the signature 20 from the rotary gripper 26, the upper and lower rollers 28, 30 are rotated about their respective axes in a direction opposite to the direction in which they receive the signature from the tape system 22. The tangential velocity of the surface of the upper and lower rollers 28, 30 as they rotate about their respective axes is subtracted from the tangential velocity of the nip 32 rotating about the center of the deceleration drum 10A to yield an additional deceleration of the signature 20. By controlling the rotational velocity of the upper and lower rollers 28, 30 at the delivery point, the velocity of the signature 20 can be made to match the velocity of the delivery system for a smooth transfer.
FIG. 9 shows a signature 20 entering the in-running nip 32 of the rotating gripper 26. A cam 34 and linkage 36 are shown as one means of controlling the velocity of the rotary gripper 26 to achieve a velocity match with the signature 20 in control of the tape conveyor system 22. The pivot arm 12/control link 16 and pivot disc 14/control disc 18 mechanism described above and shown in FIGS. 1, 2 and 8 is an another means of controlling the velocity of the rotary gripper 26. The reference numeral 38 shows the signature 20 after the rotation of the upper and lower roller 28, 30 has stopped with the desired amount of the signature 20 driven past the nip 32. The reference numeral 40 shows the signature 20 as it is just being released by the outrunning nip 32 of the rotary gripper 26. FIG. 9 shows one possible embodiment of the rotary gripper 26. In this embodiment the deceleration drum 10A provides mounting for four sets of upper and lower rollers 28, 30 with a cam controlled linkage system 34, 36 controlling the velocity of the upper and lower rollers 28, 30. As noted above, other arrangements may be provided for controlling the velocity of the upper and lower rollers 28, 30.
FIG. 10 shows one possible delivery mode where the tangential velocity of the signature 20 as it is released from the rotary gripper 26 approaches zero. The signature 20 is registered against a fixed member 44. Damage to the signature 20 due to impact against the registration member is minimized because of its near zero tangential velocity. The signatures 20 settle vertically along the registration member 44 and form a vertical stack 46.
FIG. 11 shows another possible delivery mode where the tangential velocity of the signature 20 as it is released from the rotary gripper 26 matches the speed of a tangential delivery system 48, e.g., a single copy gripper conveyor or a delivery belt system.
FIG. 12 shows a further embodiment of the rotary gripper 26A defined by oppositely rotating upper and lower rollers 28A, 30A mounted on an outward end of a pivot arm 12A that rotates into position in front of a signature 20A being released by a tape conveyor 22A. The pivot arm 12A is mounted at its inward end to a rotating disc 50 which is driven by a known acceleration/deceleration device, such as the one disclosed in U.S. Pat. No. 4,629,175. In this embodiment, the tangential velocity of the nip point 32A about the center of the deceleration drum 10B is not constant. The tangential velocity of the surface of the upper and lower rollers 28A, 30A as they rotate about their respective centers is superimposed upon the tangential velocity of the nip point 32A. The result of this superposition is a constant velocity that matches the velocity of the signature 20A exiting the tape conveyor 22A. The upper and lower rollers 28A, 30A rotate in reverse to release the signature 20A in a shingled fashion.
While the present invention is capable of various modifications and alternative constructions, it is not intended to limit the invention to the specific embodiments disclosed herein. Rather, it is intended to cover all modifications within the spirit and scope of the invention as expressed in the claims.
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A device for slowing down signatures being transported in a folding machine is provided. The device provides a plurality of rotary grippers which positively grip signatures exiting a tape conveyor system in the folding machine traveling at a high velocity. A deceleration drum is also provided for slowing down the signatures through a smooth velocity profile. The deceleration drum has a plurality of pivot arms pivotally mounted on a pivot disc rotating about a first axis, the pivot arms being connected to a control disc by a control link, the control disc rotating about a second axis parallel to, and offset from, the first axis. The rotary grippers are attached to outward ends of the pivot arms. The rotary grippers grip the leading edges of the signatures as they exit the tape conveyor system while the trailing edges are still being controlled by the tape conveyor device. The deceleration drum may alternatively be constructed of a cam and linkage system in place of the pivot arm/pivot disc and control link/control disc mechanism.
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FIELD OF THE INVENTION
The present invention relates to sighting devices primarily for shotguns and hand guns, in particular to gun sights which provide an illuminated mark to indicate proper gun pointing at moving targets.
BACKGROUND OF THE INVENTION
As distinct from precision target shooting wherein the shooter takes precise aim of a target through a pair of sights disposed at the extremes of the gun barrel, a moving target shooter adopts a different strategy, of accurately "pointing" the gun barrel after raising, or "mounting" the gun. In less than 11/2 seconds, the moving target, or "wing" shooter must first acquire the target in his view, second determine the proper position at which to point the gun. Simultaneously with acquiring the target, the shooter must mount the gun and acquire optimum pointing control of the gun. Moreover, it is preferable that while determining the proper position at which to point the gun, the gun is simultaneously pointed to that position and thereafter fired. However, traditional gun sights require the shooter to alternate between or compromise the target and gun related tasks, reducing accuracy.
Gun pointing aids such as single point sights located at the distal end of the barrel are intended to simplify the pointing process; however, as both eyes can see the same single point sight, it is instantly ambiguous which perceived point corresponds to the proper gun pointing. Attempts to interpose a lateral shield to cut off the view from the non-shooting eye are often ineffective during the mounting phase of shooting, and add little or nothing to aid the further optimization of pointing once the gun is mounted.
Sights mounted on the distal end of the gun barrel presenting an illuminated light having restricted range of viewing requires the shooter to limit the range of distal end gun motion and to fairly exactly point the gun barrel before the light begins to be seen. Alternately, a highly collimated light as may be provided by a long (>12") collimating tube delays or confuses the shooter by making it difficult to acquire the sight. Moreover, once seen, the light adds no further guidance on improving the pointing of the gun barrel, or precise targeting if sufficient time is available.
SUMMARY OF THE INVENTION
The present invention provides a shotgun or handgun pointing sight mountable on the barrel near the trigger housing comprising a fluorescent plastic member providing illumination according to the ambient light intensity, and a substantially surrounding member which provides a shooting eye indicator of optimum barrel alignment. In the preferred embodiment, an elongated tubular member contains a fluorescent plastic rod at its end and continuing forward of the end to receive light energy from the surrounding ambient light, which is then viewable from within the elongated tube by the shooting eye of the shooter when the shooter properly mounts and points the gun.
An further improvement according to the present invention comprises a multiple coaxially disposed plastic rod having contrasting fluorescent color plastic rods, wherein the inner rod extends proximally toward the shooter to offer the shooter varying fluorescent color patterns or intensities as the gun is moved to become optimally mounted by the shooter.
Still further embodiments provide an elongated tubular member to substantially surround the fluorescent rods to provide physical protection to the fluorescent plastic members. The tubular member includes one or more apertures to reveal the fluorescent plastic material to the ambient light.
Thus, according to the present invention, additional indicators by which shooter can effect the optimal mounting and pointing of the gun which provide the appropriate illumination for easy sighting and without the need for gun sight focusing.
BRIEF DESCRIPTION OF THE DRAWING
These and further features of the present invention will be better understood by reading the following Detailed Description together with the Drawing, wherein
FIG. 1 is an exemplary view of a shotgun including the rearward mounted gun sight according to one embodiment of the present invention;
FIG. 2 is a cross-sectional elevation view of one embodiment of the gun sight according to one embodiment of the present invention;
FIGS. 2A-2C are a sequence of perspective views of the proximal end of the embodiment of FIG. 2 as illustrated from the perspective of a lateral sighting motion;
FIG. 2D is an elevation of the distal end of one embodiment of the present invention;
FIG. 3 is a cross-sectional elevation view of one embodiment of the gun sight according to one embodiment of the present invention;
FIGS. 3A-3C are a sequence of perspective views of the proximal end of the embodiment of FIG. 3 as illustrated from the perspective of a lateral sighting motion;
FIG. 4 is an elevation view of a further alternate embodiment according to the present invention;
FIG. 4A is a plan view of the embodiment of FIG. 4;
FIG. 4B is a further alternate embodiment having a rounded, covered distal end of the embodiment of FIG. 4; and
FIG. 5 is an partial exploded view of one embodiment of the present invention, including an optional night illumination source.
DETAILED DESCRIPTION OF THE INVENTION
A shotgun 54 and gun sight 52 are shown together 50 in FIG. 1, wherein the gun sight 52 is mounted close to the trigger housing 56. A gun sight can be mounted at the distal end (tip) of the shotgun barrel, as illustrated in phantom, if desired. When the shooter mounts the gun, the rearward mounting of the sight encourages a more balanced raising of the shotgun by allowing the shooter to attend to a region closer to the center of the gun.
The rearward gun sight according to one embodiment 52A of the present invention includes a fluorescent plastic element partially received within an elongated member 64 which substantially surrounds the received portion of the fluorescent plastic element 62. The elongated member inner surface 61 has an non-reflective coating or is made substantially non-reflective. The distal end elevation view of FIG. 2D illustrates an extension 63 of the member 64 along one side fluorescent plastic material to restrict the view of the distal portion of the fluorescent material by a non-shooting (left) eye; the opposite shooting eye configurations provide extension 63 on the opposite side of the fluorescent plastic material 62. Typically, the elongated member comprises a tubular member, but also may comprise a C-shaped, rectangular-shaped cross-sectional member. A sight configured and mounted (with a suitable bow mounting device) on a shotgun/rifle has a length from the proximal end to the proximal end of the fluorescent plastic element 62 of 6-8 inches for a horizontally viewable end dimension of the fluorescent plastic member of less than 5/16 inch, or preferably a round pattern of 3/16 inch for a thin-walled (formed sheet metal) tubular member, and correspondingly less if the tubular member has a significant thickness. A sight configured for handgun or archery mounting has a length from the proximal end of the tubular member to the proximal end of the fluorescent plastic of 11/2 to 3 inches and a horizontally viewable fluorescent plastic element in the 0.1 to 3/16 inch range, typically a round pattern of 1/8 inch diameter.
When connected to the shotgun 54 (or handgun) by suitable fastening devices 58, the gun sight of FIG. 2 line of sight is in parallel alignment with the gun barrel providing the shooter with a sight mark viewable only by the shooting eye as shown in the FIGS. 2A-2C, as the gun is moved into optimum pointing position. The view 60A is observed when the gun is slightly laterally (to the right) displaced from optimum, and gradually, e.g. 60B, becomes optimal, 60C as the gun barrel and eye sighting line are moved into alignment.
Similarly, the further improvement according to one embodiment 52B of the present invention as shown in FIG. 3 provides an inner 65 and outer 66 fluorescent contrasting plastic members of generally concentric circular configuration. The proximal end 67 of the inner fluorescent member 65 is cantilevered beyond the outer fluorescent member 66, wherein the exposed (cylindrical) surface may further provide a contrasting or non-fluorescent surface which is viewable to the shooter when the gun sight is non-optimally aligned, as discussed below. Optionally, the outer fluorescent plastic material 66 may be tapered or shaped to reveal the inner fluorescent material, permitting both fluorescent materials 65, 66 to receive the ambient light energy; alternately, the inner fluorescent material may extend beyond the outer fluorescent material. A further feature according to the present invention provides adjustment of the position and length of the inner fluorescent plastic member 65 to vary the relative intensity of the fluorescence of that member, and to provide a more greater inner extension 67 to provide enhanced indication of optimal positioning. Thus, the gun sight of FIG. 3 also provides the shooter with a sight mark viewable only by the shooting eye as shown in the FIGS. 3A-3C, as the gun is moved into optimum pointing position. The view 70A is observed when the gun is slightly laterally (to the right) displaced from optimum, and gradually, e.g. 70B, becomes optimal, 70C as the gun barrel and eye sighting line are moved into alignment.
The embodiment 52C of FIGS. 4 and 4A provides a tubular member 72 having a distal aperture 74 to reveal the fluorescent plastic member 66A, without requiring the fluorescent plastic members to extend beyond the distal end of the tubular member 72. When the inner fluorescent member 65A (or additional members, not shown) are included, the outer fluorescent plastic members, e.g. 66A, may be themselves include an aperture 76 to reveal the inner fluorescent plastic members to receive the ambient light energy. Alternatively, the inner fluorescent plastic member(s) may extend beyond the distal end of the tubular member 72.
An alternative distal end 78 of the tubular member 72 is shown in FIG. 4B, which provides a rounded end covering.
A partial, exploded view of one embodiment of the present invention including concentric fluorescent plastic members 65B and 66B, which are to be received in the distal end of the tubular member 72, is shown in FIG. 5. Also included is a cylindrical member 82 comprising a stored-light energy or self-energized source of illumination, e.g. tritium, which is received over the inner fluorescent plastic member 65B to provide illumination viewable on the inner surface(s) of the fluorescent plastic members 65B and 66B when the gun sight is optimally pointed. Also according to the present invention, a small lamp (not shown) may be mounted externally nearby to provide local `ambient` illumination or illumination directly to the external surfaces of the fluorescent plastic material.
The preferred embodiment comprises exemplary fluorescent plastic members; however, for the purpose of the invention and the specification, such members shall include all optical material, e.g. transparent or translucent plastic or glass, etc., capable of receiving and retransmitting ambient light. These and further embodiments provided according to modifications and substitutions of one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the claims which follow.
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An elongated opaque member having a longitudinal recess including a fluorescent mark at the distal end thereof viewable only by the shooting eye of the shooter when the elongated member is mounted at the proximal end of the gun barrel. The fluorescent mark typically comprises an elongated plastic member partially extending forward of the elongated opaque member, or alternately within the distal end of the elongated opaque member and revealed by an aperture provided within the elongated opaque member. Further alternate embodiments provide additional contrasting fluorescent material surrounding the fluorescent mark for enhanced sighting accuracy.
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[0001] The present application is based on Japanese Patent Applications Nos. 2002-141978 and 2002-200361, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an air intake apparatus for supplying an air to an engine, and in particular to an air intake apparatus enabling to suppress air suction noise. The present invention also relates to an air cleaner for filtering a sucked air to be led to an engine.
[0004] 2. Description of the Related Art
[0005] A schematic view of the air intake apparatus is shown in FIG. 19 . As seen in the same, the air intake apparatus 100 comprises an air intake duct 101 , a resonator 110 , an air cleaner 103 , an air cleaner hose 104 , a throttle body 105 , and an intake manifold 106 . In the intake apparatus 100 , the reoccurs a problem about noises (called as “air suction noise” hereafter) getting out from an air intake port 102 of the intake duct 101 .
[0006] FIG. 20 shows frequency distributions of suction noises without disposing the resonator 110 and a throttled part 111 . As seen, the suction noise has plural resonance peaks. Of these plural resonance peaks, for example, a resonance peak A around 160 Hz is caused by a primary resonance mode of the intake duct 101 . A peak B around 320 Hz is caused by a secondary resonance mode of the intake duct 101 . A peak C around 260 Hz is caused by the primary resonance mode of the air cleaner hose 104 . The resonance peaks above 150 Hz are caused by members respectively composing the intake apparatus 100 . Accordingly, if changing length of paths of the respective members, the resonance peaks may be comparatively easily adjusted. Therefore, the resonator 110 small in capacity may be adopted for lowering the resonance peaks existing in middle and high frequency ranges.
[0007] However, more noise reduction has been required over the whole range of the frequency of the noise to improve amenities of the inside of the car.
[0008] Further, a resonance peak D named as so-called low frequency heavy noise is not caused by each of members composing the intake apparatus 100 . The resonance peak D is caused in the full length of the intake path 107 from the intake port 102 to the intake manifold 106 . The intake apparatus 100 takes a pipe passage of one-side closed end where the intake port 102 is an opening end, while an intake valve (not shown) partitioning the intake manifold 106 and a combustion chamber 109 otherwise an upper face of a piston, are a closing end. Thus, the resonance peak D in the low frequency range is caused in the full length of the intake path 107 . If the frequency of the resonance peak D agrees with an air pulsation transmitted from the side of the engine, the air suction noise radiated from the intake port 102 is made large. It is therefore difficult to lower the resonance peak D, that is, to suppress the low frequency heavy noise.
[0009] For suppressing the low frequency heavy noise, the intake duct 101 or the air cleaner 103 of the intake apparatus 100 is arranged with the resonator 110 of comparatively large capacity as around 2×10 −3 to 10 −2 m 3 .
[0010] There is often a case that a throttled part 111 is often arranged together with the resonator 110 of large capacity nearly the intake port 102 of the intake duct 101 for increasing acoustic mass and decreasing the air sucking noise.
[0011] But, as mentioned above, the resonator 110 for controlling the low frequency heavy noise is comparatively large in the capacity, and a whole of the intake apparatus 100 is made large accordingly, so that spaces for mounting other devices than the intake apparatus 100 are made narrow.
[0012] If the area of the intake path is throttled by the throttled part 1111 an air flow rate to be supplied to the combustion chamber 109 decreases. In particular, when the engine rotates at high speed, a desired air flow rate is not effected, and an engine output goes down.
SUMMARY OF THE INVENTION
[0013] It is accordingly an object of the invention to provide such an air intake apparatus capable of being reduced in size, securing the desired engine output, and suppressing the noise.
[0014] (1) For solving the above problems, the air intake apparatus of the invention comprises the air intake port opening outside, and the air intake path communicating the air intake port with the combustion chamber of an engine, and is characterized in that, for suppressing noise getting out from the air intake port, with respect to walls partitioning the air intake path, an opening is provided at the part of said walls corresponding to an antinode region of resonance mode of standing wave in the full length of the intake path, or at the part of noise pressure level being high in the intake path, and said opening is closed with a permeable member and a noise insulating wall is disposed outside the permeable member for suppressing emission of transmitting noise passing through the permeable member.
[0015] In short, the air intake apparatus of the invention is provided with the opening at the part of the walls corresponding to the antinode of resonance mode, or at the part of noise pressure level being high in the intake path, and this opening is closed with the permeable member. See Unexamined Japanese Patent Publication No. 2002-21660 and “Development of low noise intake system with unreflective duct (Part 2)” published on May 24, 2000 regarding the antinode of resonance mode and noise pressure level in the air intake apparatus.
[0016] With the permeable member disposed, the inner pressure of the intake path is released outside from the interior of the intake apparatus via the permeable member, so that a standing wave is thereby suppressed from occurrence. The permeable member has lots of fine pores, and energy of noise wave entering the fine pores is converted into heat energy owing to viscous friction between the air and a wall of the fine pole, so that it is possible to effectively reduce noises (called as “air transmitting noise” hereafter) getting out from the intake path to the outside of the permeable member by air transmission loss. By these actuations, depending on the intake apparatus of the invention, the noise from the intake port may be suppressed.
[0017] Further, by the air intake apparatus of the invention, any resonator of large capacity is unnecessary or it becomes possible to reduce the capacity of the resonator. Accordingly, the whole of the intake apparatus may be reduced in size. Disposing the resonator, noise having frequency around the noise demanded to be controlled might be in turn increased by anti-resonance. So, it is necessary to carry out a tuning of the capacity of the resonator. On the other hand, since the air intake apparatus of the invention suppresses the noise by the permeable member, there is no possibility to cause anti-resonance. Accordingly, by the intake apparatus of the invention, it is unnecessary to carry out the tuning for suppression of anti-resonance.
[0018] According to the intake apparatus of the invention, it would be possible to reduce the noise even in the case where the throttle part is not formed in the intake duct. Accordingly, the air flow rate for the combustion chamber does not go down, and the desired engine output can be easily secured.
[0019] The intake apparatus of the invention is furnished with a noise insulating wall outside of the permeable member for suppressing emission of the air transmitting noise passing through the permeable member. For reducing the sucking noise, the air transmitting noise is made large, but not only the air sucking noise but the air transmitting noise cause noises.
[0020] In this regard, the intake apparatus of the invention has the noise insulating wall outside of the permeable member for blocking the transmitting noise having passed through the permeable member from further getting out outside. Accordingly, by the intake apparatus of the invention, not only the sucking noise but the transmitting noise can be controlled. In addition, it is possible to prevent reduction of permeability due to adhering of moisture, foreign materials, or the like to the permeable member according to the intake apparatus of the invention. Accordingly, noise reduction effect can be maintained in the long term.
[0021] Furthermore, according to the intake apparatus of the invention, so-called low frequency heavy noise, which is not caused by each of members composing the intake apparatus, may be easily suppressed.
[0022] (2) The resonance frequency of said noise is 200 Hz or lower in general. The noise having the resonance peak in this frequency range is especially rasping. By the present structure, this rasping noise can be concentrically suppressed.
[0023] (3) In case there is present, in the air cleaner, the part of the walls corresponding to the antinode region of the resonance mode of the standing wave in the full length of the intake path, or the part of noise pressure level being high in the intake path, it is enough to determine the opening is provided in the air cleaner.
[0024] In short, the present structure disposes the permeable member and the noise insulating wall in the air cleaner. The wall part of the air cleaner has many planes of face-structure in comparison with wall parts of other members forming the intake apparatus. Accordingly, following this structure, the opening can be comparatively easily provided, and the permeable member is easily and cheaply disposed.
[0025] Desirably, since the permeable member is clogged when the water or dusts invade into the air cleaner from the side of the intake duct, so that it is difficult to release the air sucking pulsation pressure from the inside to the outside, the reducing effect of the desired air sucking noise cannot be obtained, and an opening is provided at another wall part than the bottom wall of the air cleaner for arranging the permeable member there.
[0026] (4) In case there is present, in a clean side of the air cleaner, the part of the walls corresponding to the antinode region of the resonance mode of the standing wave in the full length of the intake path, or the part of noise pressure level being high in the intake path, it is enough to determine the opening is provided in the clean side of the air cleaner.
[0027] The air cleaner is divided by an air filter into an upstream side communicating with the intake port, i.e., a dirty side and a downstream side communicating with the combustion chamber, i.e., the clean side. The sucked air is filtered by passing through the air filter. In this structure, the permeable member and the noise insulating wall may be disposed at the clean side.
[0028] (5) In case there is present, in a dirty side of the air cleaner, the part of the walls corresponding to the antinode region of the resonance mode of the standing wave in the full length of the intake path, or the part of noise pressure level being high in the intake path, it is enough to determine the opening is provided in the dirty side of the air cleaner.
[0029] (6) In case there is present, in the air cleaner hose, the part of the walls corresponding to the antinode region of the resonance mode of the standing wave in the full length of the intake path, or the part of noise pressure level being high in the intake path, it is enough to determine the opening is provided at least in the air cleaner hose.
[0030] The structure disposes the permeable member and the noise insulating wall in the air cleaner hose. The air cleaner hose is disposed at the downstream side of the air cleaner.
[0031] (7) In case there is present, in an intake duct, the part of the walls corresponding to the antinode region of the resonance mode of the standing wave in the full length of the intake path, or the part of noise pressure level being high in the intake path, it is enough to determine the opening is provided in the part of the intake duct.
[0032] (8). The permeable member preferably has a water repellent property. Following this structure, it is possible to suppress the amount of the moisture entering the inside of the intake path through the permeable member.
[0033] (9) Desirably, it is sufficient that the noise insulating wall is structured to have a vibration control member for the noise insulating wall not to cause face-vibration of the permeable member owing to the transmitting noise from the permeable member. When the air transmitting noise reaches the noise insulating wall, the noise insulating wall itself probably generates the face-vibration by the air transmitting noise, and by this face-vibration, a new noise might be caused as a noise source becoming the noise insulating wall itself.
[0034] In this point, the noise insulating wall of this structure has the vibration control member for the noise insulating wall. Accordingly, following the structure, the noise insulating wall is less to make the face-vibration, and the noise insulating wall itself is difficult to generate noises.
[0035] (10) For solving the above problems, the air intake apparatus of the invention comprises an air intake port, and an air intake path communicating with the air intake port and the combustion chamber of an engine, and is characterized in that, for suppressing noise emitted from the air intake port, with respect to walls partitioning the air intake path, the opening is provided at the part of said walls corresponding to the antinode region of resonance mode of standing wave in the full length of the intake path, or at the part of noise pressure level being high in the intake path, and said opening is closed with the permeable member and has a noise insulating wall for insulating transmitting noise passing through the permeable member, and has vibration control members for suppressing face-vibration of the permeable member and reducing radiant noise from the permeable member.
[0036] In short, the air intake apparatus of the invention has the permeable member and the vibration control member. As mentioned above, for lowering the air sucking noise, the transmitting noise is made large. But if an area of disposing the permeable member is enlarged, the permeable member itself probably produces the face-vibration, and by this face-vibration, a new noise might be caused as a noise source being the noise insulating wall itself.
[0037] In this point, the air intake apparatus of the invention has the vibration control member for suppressing the face-vibration of the permeable member. According to this structure, even if an area of disposing the permeable member is enlarged, the permeable member is less to make the face-vibration. Therefore, new noises caused by the permeable member itself can be suppressed.
[0038] Further, an air cleaner, enabling to suppress not only air suction noises but also air transmitting noises and decrease the number of parts is provided according to the present invention.
[0039] (11) For settling the above problems, an air cleaner of the invention comprises a case, an element partitioning the case into a dirty side and a clean side, and a permeable member sectioning a compartment room in the case, and this is characterized in that a noise insulating wall part is formed as one body within the case, said noise insulating wall part being provided with communicating holes for communicating the compartment room with the outside of the case.
[0040] In short, the air cleaner of the invention supports the permeable member within the case, and unifies the noise insulating wall to the case wall. The compartment room is partitioned with the permeable member and sectioned within the case. That is, in the case, an exterior and an interior of the compartment room are partitioned by the permeable member. The noise insulating wall part is disposed outside of the compartment room and has communicating holes through which the compartment room communicates with the exterior of the case.
[0041] Sound pressure runs along a passage of the exterior of the compartment room→the permeable member→the interior of the compartment room→the noise insulating wall part (communicating holes)→the outside of the case, and gets out from the interior to the exterior of the case. During getting out, a major part of sound pressure having transmitted the permeable member collides against other parts than the communicating holes of the noise insulating wall part, namely, the wall part. By this collision, the air transmitting noise is not directly released outside of the case, but acoustic mass is increased by the communicating holes so that the air transmitting noise can be suppressed.
[0042] According to the air cleaner of the invention, not only the air suction noise but the air transmitting noise can be suppressed. Accordingly, in case a noise insulating property is low in a part of installing the air cleaner (e.g., engine room), if installing the air cleaner of the invention, the suppression is especially effective. A reason therefor is because the air cleaner of the invention itself has the high noise insulating property and does not depend on a noise insulating property of the part of installing the air cleaner.
[0043] According to the air cleaner of the invention, the noise insulating wall part is formed as one body with the case. Therefore, in comparison with a case of forming the noise insulating wall part independently of the case, constituting parts may be reduced in number, a production cost may be saved accordingly and attachment of the air cleaner is made easy.
[0044] (12) Desirably, the noise insulating wall part is arranged at the dirty side of the case. If arranging the noise insulating wall part at the dirty side, even if dusts invade within the case of the air cleaner through the noise insulating wall part and the permeable member, dusts are filtered through the element. Therefore, it is easy to suppress dusts invading from the clean side of the case into a downstream side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] In the accompanying drawings:
[0046] FIG. 1 shows a schematic view of the air intake apparatus based on the first embodiment of the invention;
[0047] FIG. 2 shows a disassembled view of the air cleaner incorporated in the air intake apparatus based on the first embodiment of the same;
[0048] FIG. 3 shows a graph showing the frequency distributions of the air sucking noises of the air intake apparatus based on the first embodiment;
[0049] FIG. 4 shows a partially disassembled view of the air cleaner incorporated in the air intake apparatus based on the second embodiment;
[0050] FIG. 5 shows a graph showing the frequency distributions of the air suction noises of the air intake apparatus based on the second embodiment;
[0051] FIG. 6 shows a graph showing the frequency distributions of the air transmitting noises of the air intake apparatus based on the second embodiment;
[0052] FIG. 7 shows a partially disassembled view of the air cleaner incorporated in the air intake apparatus based on the third embodiment;
[0053] FIG. 8 shows a graph showing the frequency distributions of the air sucking noises of the air intake apparatus based on the third embodiment;
[0054] FIG. 9 shows disassembled views of the air intake duct and the air cleaner incorporated in the air intake apparatus based on the fourth embodiment;
[0055] FIG. 10 shows a graph showing the frequency distributions of the air sucking noises of the air intake apparatus based on the fourth embodiment;
[0056] FIG. 11A shows a cross sectional view of the air cleaner incorporated in the air intake apparatus based on the fifth embodiment, and FIG. 11B shows a partial perspective view of the air cleaner based on the fifth embodiment;
[0057] FIG. 12 shows a cross sectional view of the air cleaner incorporated in the air intake apparatus based on the sixth embodiment;
[0058] FIG. 13 shows a schematic view of the air intake system incorporated with the air cleaner of the seventh embodiment of the invention;
[0059] FIG. 14 shows a disassembled view of the air cleaner of the seventh embodiment;
[0060] FIG. 15 shows frequency distributions of air suction noises in the air intake system incorporated with the air cleaner of the seventh embodiment;
[0061] FIG. 16 shows frequency distributions of air transmitting noises in the air intake system incorporated with the air cleaner of the seventh embodiment;
[0062] FIG. 17 shows a disassembled view of the air cleaner of the eighth embodiment;
[0063] FIG. 18 shows a perspective view of the air cleaner of the ninth embodiment;
[0064] FIG. 19 shows a schematic view of the conventional air intake apparatus;
[0065] FIG. 20 shows a graph showing the frequency distributions of the air sucking noises of the conventional air intake apparatus; and
[0066] FIG. 21 shows an enlarged view of the air cleaner hose where the permeable member is attached on the hose.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0067] Further explanation will be made to embodiments of the air intake apparatus according to the invention.
(1) First Embodiment
[0068] At first, the structure of the embodied intake apparatus will be referred to. A schematic view of the air intake apparatus of the embodiment is shown in FIG. 1 . As seen in the same, the air intake apparatus 1 comprises the air intake duct 3 , the resonator 4 for middle and high frequencies, the air cleaner 5 , the air cleaner hose 6 , the throttle body 7 , the intake manifold 2 and the permeable member 8 . In the interior of these members, the air intake path 10 from the air intake port 30 to the intake manifold 2 is sectioned.
[0069] The intake duct 3 is made of a resin taking a cylindrical shape, and communicates with an outside of a vehicle via the intake port 30 provided at an upstream end. The resonator 4 for middle and high frequencies is generally made of the resin taking a box shape. The resonator 4 is branched and connected to the intake duct 3 at its middle part in this embodiment but it may be located in other fashions within the air intake apparatus. A capacity, a shape or a communicating part with the intake duct 3 of the resonator 4 are effected with tuning for lowering the resonance peak in the middle and high frequencies of the air sucking noise.
[0070] The air cleaner 5 has the dirty side case 50 , the clean side case 51 , and an element 52 . FIG. 2 shows a disassembled view of the air cleaner. As shown in the same, the dirty side case 50 is made of the resin taking the box shape opening upward, and projects a duct connecting cylinder 500 from a side wall thereof, the duct connecting cylinder 500 being connected to the downstream end of the intake duct 3 shown in FIG. 1 .
[0071] The clean side case 51 is made of the resin taking the box shape opening downward, mounted on the dirty side case 50 under a condition of turning over the opening, and projects a hose connecting cylinder 510 from a side wall 51 thereof. On an inside of the side wall of the clean side case 51 and an inside of an upper bottom wall, a plurality of U-shaped reinforcing ribs 53 stand following the insides. In the upper bottom wall of the clean side case 51 , an oblong opening 80 is formed. A reason why the 80 is formed in the upper bottom wall of the clean side case 51 is because it has been proved by a preliminary simulation analysis that there is positioned an antinode region of the resonance secondary mode of the standing wave at one-side opening end. On the upper bottom wall of the clean side case 51 is included in the wall part of the invention. From the opening 80 , the reinforcing ribs are seen in stripe.
[0072] The element 52 is a rectangular pleat-process PET non-woven fabric, secured between opening edges of the dirty side case 50 and the clean side case 51 and partitions a closed space defined between the dirty side case 50 and the clean side case 51 into upper and lower chambers.
[0073] The permeable member 8 is the PET non-woven fabric taking the rectangular shape. The permeable member 8 may be a woven fabric, a PP non-woven fabric, or the like as far as being permeable. The permeable member 8 closes the opening 80 under a condition that it is supported from the lower part by the reinforcing ribs. The reinforcing ribs 53 are included in the vibration control member of the invention. The permeable member 8 is secured to a periphery of the opening 80 and the reinforcing ribs 53 by known means such as inserting or fusing.
[0074] Turning to FIG. 1 , the air cleaner hose 6 is made of rubber or resin taking a bellows cylinder, and is connected at its upstream end to the resin-made hose connecting cylinder 510 shown in FIG. 2 . The air cleaner hose 6 is connected at its downstream end to the upstream end of the throttle body 7 which is connected at its downstream end to the intake manifold 2 branched to the combustion chamber. The air sucked from the outside passes in order of the intake duct 3 →the dirty side case 50 →the element 52 →the clean side case 51 →the air cleaner hose 6 →the throttle body 7 →the intake manifold 2 , and goes into the combustion chamber 20 .
[0075] Next, effects brought about by the air intake apparatus 1 of the embodiment will be referred to. FIG. 3 shows the frequency distributions without disposing the resonator 4 for the middle and high frequencies and the reinforcing ribs 53 . By the way, the frequency distributions were measured by generating white noises from a speaker placed at the downstream of the intake manifold 2 and collecting the air sucking noise. In the figure, a solid line is the frequency distribution without the permeable member shown in FIG. 14 . In the same, a dotted line is the frequency distribution with the permeable member of thickness t=1 mm. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm. In regard to the permeable member, the PET non-woven fabric of raw fabric weight being 840/m 2 and the PET non-woven fabric of raw fabric thickness (before a hot-pressing) being 5 mm are subjected to the hot press to change thickness for changing quantity of airflow.
[0076] As shown, if disposing the permeable member, the resonance peak E of the low frequency heavy noise goes down. Practically, in case of t=1 mm, the resonance peak E lowers by about 3 dB, while in case of t=2 mm, it lowers by about 10 dB. In view of the resonance peak decreasing effect by the resonator being about 5 dB to 10 dB, it is seen that the permeable member has a substantially equivalent resonance peak decreasing effect to that of the resonator. From the fact that the decreasing rate of the resonance peak E is larger in t=2 mm than t=1 mm, it is seen that the larger is the thickness of the permeable member, the lower is the density, the larger is the resonance peak decreasing effect in sucking noise. Hereupon, by suppressing the compression amount of the raw member for the permeable member during the manufacturing process of the permeable member, the density of the permeable member can be lowered and its permeability is made higher. Further, it is seen that the resonance peak decreasing effect is large in the low frequency range of in particular more than 30 Hz to less than 150 Hz.
[0077] According to the intake apparatus 1 of the embodiment, any resonator of large capacity is unnecessary or it becomes possible to reduce the capacity of the resonator. The whole of the intake apparatus 1 can be therefore reduced in size. Further, according to the permeable member 8 in the intake apparatus 1 of the embodiment, there is no possibility of causing anti-resonance. The noise can be therefore more easily suppressed. Depending on the intake apparatus 1 of the embodiment, the noise can be effectively controlled without placing the throttle in the air intake duct 3 . The desired engine output can be easily therefore secured.
[0078] The intake apparatus 1 of the embodiment is furnished with the reinforcing ribs 53 as the vibration control member. Therefore, even if the area of the air passing is large in the permeable member 8 , possibility of the permeable member 8 causing the face-vibration is scarce. The reinforcing ribs 53 may be formed of the same material as that of the clean side case 51 , i.e., the air cleaner case, may be formed at the same time as forming the air cleaner case, and may be formed by inserting the permeable member 8 when forming the air cleaner case so as to unify the air cleaner case and the permeable member 8 and concurrently unify the permeable member 8 and the reinforcing ribs 53 . In addition, the permeable member 8 of the embodied air intake apparatus 1 may be placed at the clean side of the air cleaner case.
(2) Second Embodiment
[0079] A difference of this embodiment from the first embodiment is that the noise insulating wall is arranged outside of the permeable member.
[0080] At first, explanation will be made to a structural difference of the intake apparatus of this embodiment. FIG. 4 shows a partially disassembled view of the air cleaner incorporated in the air intake apparatus based on this embodiment. The same numerals will be given to parts corresponding to those of FIG. 2 . As seen, the noise insulating wall 81 is made of the resin, taking the rectangular plate shape with pin holes 810 at four corners. On the other hand, pins 82 stand corresponding to the pin holes 810 from four corners in an outer surface of an upper bottom wall of the clean side case 51 . The pins 82 are mounted thereon with resin-made spacers 83 shaped in cylinder, and fitted in the pin holes 810 via the cylindrical spacers 83 .
[0081] Next, explanation will be made to different effects of this embodied air intake apparatus from those in the first embodiment. FIG. 5 shows the frequency distributions of the air suction noises without disposing hen the resonator 4 for middle and high frequencies. In the figure, the solid line is the frequency distribution without the permeable member shown in FIG. 20 . In the same, the dotted line is the frequency distribution with the only permeable member of thickness t=2 mm and without the noise insulating wall. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=1 mm from the permeable member. Two-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=10 mm from the permeable member.
[0082] As shown, in the case of L=1 mm, comparing with a case of having the only permeable member and not having the noise insulating wall, the resonance peak E of the low frequency heavy noise its high. In the case of L=10 mm, comparing with the case of having the only permeable member and not having the noise insulating wall, the resonance peak E of the low frequency heavy noise is almost at the same height. From this fact, it is seen that the larger is the distance width L, the larger is the effect of reducing the air sucking noise.
[0083] FIG. 6 shows the frequency distributions of the air transmitting noises without arranging the resonator 4 for middle and high frequencies. The transmitting noise is collected by disposing the microphone outside of the noise insulating wall 81 . In the figure, the solid line is the frequency distribution without the permeable member. In the same, a dotted line is the frequency distribution with the only permeable member of thickness t=2 mm and without the noise insulating wall. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=1 mm from the permeable member. Two-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=10 mm from the permeable member.
[0084] As shown, in the case of L=1 mm, comparing with a case of having the only permeable member and not having the noise insulating wall, the resonance peak F of the low frequency heavy noise is low by around 5 dB. In the case of L=10 mm, comparing with the case of having the only permeable member and not having the noise insulating wall, the resonance peak F of the low frequency heavy noise is low by around 5 dB. Only, in view of the whole of the frequency distributions, each of the resonance peaks is lower in L=1 mm than L=10 mm. From this fact, it is seen that the smaller is the distance width L, the larger is the effect of reducing the transmitting noise.
[0085] From FIGS. 5 and 6 , it is seen that with the disposal of the noise insulating wall 81 , almost equivalent effects of lowering the transmitting noise are brought about in comparison with the case of not disposing the noise insulating wall 81 but disposing the only permeable member 8 . Further, it is seen that with the disposal of the noise insulating wall 81 , large effects of lowering the transmitting noise are brought about in comparison with the case of not disposing the noise insulating wall 81 but disposing the permeable member 8 only. In addition, if changing the separating width L, it is seen that the air suction noise and the transmitting noise may be balanced.
[0086] Accordingly, depending on the air intake apparatus 1 of this embodiment, not only the air sucking noise but also the transmitting noise can be controlled. By changing the separating width L, the air sucking noise and the transmitting noise may be best balanced. That is, it is sufficient that the separating width L is set at an optimum value, taking, for example, noise interrupting property in the engine room or clog preventing effect of the permeable member into consideration. The noise insulating wall 81 itself may be a permeable member of lower permeability than that of the permeable member arranged in the air cleaner case.
(3) Third Embodiment
[0087] A difference of this embodiment from the second embodiment is that the permeable member and the noise insulating wall are arranged at the dirty side case. Therefore, this difference will be referred to herein.
[0088] At first, explanation will be made to a structural difference of the intake apparatus of this embodiment. FIG. 7 shows a disassembled view of the air cleaner incorporated in the air intake apparatus based on this embodiment. The same numerals will be given to parts corresponding to those of FIG. 4 . As seen, the rectangular opening 80 is provided at the side wall of the dirty side case 50 . The permeable member 8 closes the opening 80 . The noise insulating wall 81 is disposed outside of the permeable member 8 .
[0089] Next, explanation will be made to effects of this embodied intake apparatus. FIG. 8 shows the frequency distributions of the air sucking noises when the resonator 4 for middle and high frequencies is not disposed. In the figure, the solid line is the frequency distribution without the permeable member shown in FIG. 14 . In the same, the dotted line is the frequency distribution with the permeable member of thickness t=1 mm. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm.
[0090] As shown, if disposing the permeable member, the resonance peak E of the low frequency heavy noise goes down. Practically, in case of t=1 mm, the resonance peak E lowers by about 5 dB, while in case of t=2 mm, it lowers by about 10 dB. From this fact, it is seen that the permeable member 8 has an almost equivalent effect of decreasing the resonance peak to that of the resonator. In view that the decreasing rate of the resonance peak E is larger in t=2 mm than t=1 mm, it is seen that the larger is the thickness of the permeable member, that is, the higher is the permeability of the permeable member, the larger is the resonance peak decreasing effect. Further, it is seen that the resonance peak decreasing effect is large in the low frequency range of in particular more than 30 Hz to less than 150 Hz. Also in the intake apparatus of this embodiment, the noise may be suppressed.
(4) Fourth Embodiment
[0091] A difference of this embodiment from the second embodiment is that the permeable member and the noise insulating wall are arranged in the vicinity of the downstream of the intake duct. Therefore, this difference will be referred to herein.
[0092] At first, explanation will be made to a structural difference of the intake apparatus of this embodiment. FIG. 9 shows a disassembled view of the intake duct and the air cleaner incorporated in the air intake apparatus based on this embodiment. The same numerals will be given to parts corresponding to those of FIG. 4 . As seen, the rectangular opening 80 is provided at the peripheral side wall of the intake duct 3 . The permeable member 8 closes the opening 80 . The noise insulating wall 81 is disposed outside of the permeable member 8 .
[0093] Next, explanation will be made to effects of this embodied intake apparatus. FIG. 10 shows the frequency distributions of the air suction noises when the resonator 4 for middle and high frequencies is not disposed. In the figure, the solid line is the frequency distribution without the permeable member shown in FIG. 14 . In the same, the dotted line is the frequency distribution with the permeable member of thickness t=1 mm. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm.
[0094] As shown, it is seen that if disposing the permeable member, the resonance peak E of the low frequency heavy noise goes down. Further, the larger is the thickness of the permeable member, that is, the higher is the permeability of the permeable member, the larger is the resonance peak decreasing effect. Further, it is seen that the resonance peak decreasing effect is large in the low frequency range of in particular more than 30 Hz to less than 150 Hz. Also in the air intake apparatus of this embodiment, the noise may be suppressed.
(5) Fifth Embodiment
[0095] Differences of this embodiment from the second embodiment are that the noise insulating wall is shaped in cup, and the noise insulating wall is equipped with control ribs for the noise insulating wall. Therefore, the differences will be referred to herein.
[0096] FIG. 11A shows a cross sectional view of the air cleaner incorporated in the air intake apparatus based on this embodiment, and FIG. 11B shows a partial perspective view of the air cleaner of this embodiment. The same numerals will be given to parts corresponding to those of FIG. 4 . As shown, the noise insulating wall 81 takes a cup shape opening toward the clean side case 51 . Namely, the noise insulating wall 81 is arranged just as wrapping the permeable member 8 . The control ribs 811 for the noise insulating wall stand on the lower face of the upper bottom wall of the noise insulating wall 81 , and are included in the vibration control member for the noise insulating wall.
[0097] According to the embodiment, the noise insulating wall 81 is shaped in cup. Therefore, the noise insulating property is heightened. Further, the noise insulating wall 81 is equipped with control ribs 811 for the noise insulating wall. Thus, there is less possibility to generate noises by vibration of the noise insulating wall 81 itself.
(6) Sixth Embodiment
[0098] A difference of this embodiment from the fifth embodiment is that non-woven fabric layer is disposed on the inside of the cup of the noise insulating wall in substitution for the vibration ribs for the noise insulating wall. Therefore, the difference will be referred to herein.
[0099] FIG. 12 shows a cross sectional view of the air cleaner incorporated in the air intake apparatus based on this embodiment. The same numerals will be given to parts corresponding to those of FIG. 11 . As shown, the noise insulating wall 81 is laminated on the inside of the cup of the noise insulating wall with the non-woven fabric layer 812 made of PET non-woven fabric.
[0100] According to this embodiment, the non-woven fabric layer 812 may lower the transmitting noise getting out from the permeable member 8 . Thus, the transmitting noise decreasing effect is high.
[0101] In the following, explanation will be made to embodiments focusing on the air cleaner of the invention.
(7) Seventh Embodiment
[0102] At first, the air cleaner and the structure of the air intake system incorporated with d the air cleaner will be referred to. A schematic view of the air intake apparatus of the embodiment is shown in FIG. 13 . The air cleaner according to the present embodiment can be installed also in that in FIG. 1 . As seen in the same, the air intake apparatus 1 comprises the air intake duct 3 , the resonator 4 , the air cleaner 5 , the air cleaner hose 6 , the throttle body 7 , and the intake manifold 2 , which has a similar structure shown in FIG. 1 . In the interior of these members, the air intake path 10 from the air intake port 30 to the intake manifold 2 is sectioned.
[0103] The intake duct 3 has the same structure as that in FIG. 1 .
[0104] The air cleaner 5 has the dirty side case 50 , the clean side case 51 , and the element 52 . FIG. 14 shows a disassembled view of the air cleaner 5 . As shown in the same, the dirty side case 50 is made of the resin, taking the box shape opening upward, and projects a duct connecting cylinder 500 from a side wall 50 thereof, the duct connecting cylinder 500 being connected to the downstream end of the intake duct 3 shown in FIG. 13 . A bottom of the dirty side case 50 projects downward. A case wall composing this projecting part is disposed with the noise insulating wall part (noise insulating wall) 57 formed with lots of communicating holes 530 . The noise insulating wall part 57 is formed as one body with the dirty side case 50 by an injection molding. Within the noise insulating wall part 57 , the compartment room 55 is arranged. On the upper portion of the compartment room 55 , the rectangular permeable member 54 made of PET non-woven fabric is connected by fusing. That is, the upper part of the compartment room 55 is closed with the permeable member 54 . In other words, the interior of the dirty side case 50 is sectioned by the permeable member 54 into the interior of the compartment room 55 and the exterior of the compartment room 55 .
[0105] The clean side case 51 is made of the resin, taking the box shape opening downward, mounted on the dirty side case 50 under a condition of turning over the opening, and projects a hose connecting cylinder 510 from a side wall 51 thereof.
[0106] The element 52 has the same structure as that in FIG. 2 .
[0107] Next, effects brought about by the air cleaner of the embodiment will be referred to. FIG. 15 shows the frequency distributions without disposing the resonator 4 . By the way, the frequency distributions were measured by generating white noises from a speaker placed at the downstream of the intake manifold 2 and collecting the air sucking noise. In the figure, a solid line is the frequency distribution without the permeable member. In the same, a dotted line is the frequency distribution with the only permeable member of thickness t=2 mm and without the noise insulating wall part. One-dotted line is the frequency distribution with having the permeable member of thickness t=2 mm and disposing the noise insulating wall part separated by a separating width L=1 mm from the permeable member. By the way, the separating width is meant by a distance between the lower surface of the permeable member and the upper surface of the permeable member disposed on the bottom wall of the case. Further, two-dotted line is the frequency distribution having the permeable member of thickness t=2 mm and disposing the noise insulating wall part separated by a separating width L=10 mm from the permeable member. In regard to the permeable member, the PET non-woven fabric of raw fabric weight being 840/m 2 and the PET non-woven fabric of raw fabric thickness (before a hot-pressing) being 5 mm are subjected to the hot press to change thickness for changing quantity of airflow.
[0108] As shown, in the case of L=1 mm, comparing with a case of having the only permeable member and not having the noise insulating wall, the resonance peak E of the low frequency heavy noise is high. In the case of L=10 mm, comparing with the case of having the only permeable member and not having the noise insulating wall, the resonance peak E of the low frequency heavy noise is almost at the same height. From this fact, it is seen that the larger is the distance width L, the larger is the effect of reducing the air-sucking noise.
[0109] FIG. 16 shows the frequency distributions of the air transmitting noises without arranging the resonator 4 for middle and high frequencies. The transmitting noise is collected by disposing the microphone outside of the noise insulating wall 81 . In the figure, the solid line is the frequency distribution without the permeable member. In the same, a dotted line is the frequency distribution with the only permeable member of thickness t=2 mm and without the noise insulating wall. One-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=1 mm from the permeable member. Two-dotted line is the frequency distribution with the permeable member of thickness t=2 mm and the noise insulating wall arranged separated by a width L=10 mm from the permeable member. In regard to the permeable member, the PET non-woven fabric of raw fabric weight being 840/m 2 and the PET non-woven fabric of raw fabric thickness (before a hot-pressing) being 5 mm are subjected to the hot press to change thickness for changing quantity of airflow.
[0110] As shown, in the case of L=1 mm, comparing with a case of having the only permeable member and not having the noise insulating wall part, the resonance peak F of the low frequency heavy noise is low by around 5 dB. In the case of L=10 mm, comparing with the case of having the only permeable member and not having the noise insulating wall, the resonance peak F of the low frequency heavy noise is low by around 5 dB. Only, in view of the whole of the frequency distributions, each of the resonance peaks is lower in L=1 mm than L=10 mm. From this fact, it is seen that the smaller is the distance width L, the larger is the effect of reducing the transmitting noise.
[0111] From FIGS. 15 and 16 , it is seen that with the disposal of the noise insulating wall part, almost equivalent effects of lowering the transmitting noise are brought about in comparison with the case of not disposing the noise insulating wall part but disposing the only permeable member. Further, it is seen that with the disposal of the noise insulating wall part, large effects of lowering the transmitting noise are brought about in comparison with the case of not disposing the noise insulating wall part but disposing the permeable member only. In addition, if changing the separating width L, it is seen that the air suction noise and the transmitting noise may be balanced.
[0112] Thus, depending on the air cleaner 5 of this embodiment, not only the air sucking noise but also the transmitting noise can be controlled. By changing the separating width L, the air sucking noise and the transmitting noise may be best balanced. That is, it is sufficient that the separating width L is set at an optimum value, taking, for example, noise interrupting property in the engine room or clog preventing effect of the permeable member into consideration.
[0113] According to the air cleaner 5 of this embodiment, the noise insulating wall part 57 is displaced at the dirty side case 50 . Therefore, even if dusts invade into the dirty side case 50 through the noise insulating wall part 57 and the permeable member 54 , the dusts may be filtered through the element 52 , so that the dusts are controlled from invasion in the downstream side after the interior of the clean side case 51 .
[0114] According to the air cleaner 5 of this embodiment, the noise insulating wall part 57 is formed as one body with the dirty side case 50 . Therefore, comparing with a case where the noise insulating wall part 57 is formed independently of the dirty side case 50 or the clean side case 51 , parts may be reduced in number, and production cost may be saved. In addition, the structure of the air cleaner 5 itself is made simple.
(8) Eighth Embodiment
[0115] A difference of this embodiment from the seventh embodiment is that the bottom part of the dirty side case does not project. Therefore, this difference will be referred to herein.
[0116] FIG. 17 shows a disassembled view of the air cleaner of this embodiment. The same numerals will be given to parts corresponding to those of FIG. 14 . As seen, a partitioning wall 56 stands in rectangle from the bottom wall of the dirty side case 50 . The bottom part of the partitioning wall 56 is disposed with the noise insulating wall part (noise insulating wall) 57 formed with slit-like communicating holes 530 . On the upper end of the partitioning wall 56 , the permeable member 54 is connected by such as fusing. The compartment room 55 is sectioned by the partitioning wall 56 and the permeable member 54 . In the embodied air cleaner 5 , the bottom part of the dirty side case does not project, so that a space for installing the air cleaner 5 may be small.
(9) Ninth Embodiment
[0117] A difference of this embodiment from the seventh embodiment is that the noise insulating wall part is disposed in the clean side case. Therefore, this difference will be referred to herein.
[0118] FIG. 18 shows a perspective view of the air cleaner of this embodiment. The same numerals will be given to parts corresponding to those of FIG. 14 . As seen, a top portion of the clean side case 51 projects upward. A case wall composing the projecting portion is disposed with the noise insulating wall part (noise insulating wall) 57 formed with lots of communicating holes 530 , the part 57 being formed as one body with the clean side case 51 by the injection molding. The interior of the noise insulating wall part 57 is the compartment room 55 . The lower part of the compartment room 55 is connected with the permeable member 54 by such as fusing. That is, the upper portion of the compartment room 55 is closed with the permeable member 54 . In other words, the interior of the clean side case 51 is sectioned by the permeable member 54 into the interior of the compartment room 55 and the exterior of the compartment room 55 .
[0119] Depending on the embodied air cleaner 5 , by disposing the noise insulating wall part 57 , dusts from the outside of the case may be suppressed from directly adhering the permeable member 54 , so that the permeable member 54 is less to be clogged by dusts in the sucked air.
[0120] (10) Other
[0121] As above mentioned, the explanations have been made to the practiced embodiments of the air intake apparatus and the air cleaner according to the invention. However, embodiments to be reduced to practice are by no means limited to the above mentioned modes, but may be served under various deformations or improved modifications made by those skilled in the technical field.
[0122] For example, in the above embodiments, the permeable member is disposed in the vicinity of the downstream of the air cleaner or the intake duct. However, in case other members correspond to the antinode region of the resonance mode of the standing wave, the permeable member may be arranged at, e.g., other members such as the air cleaner hose. FIG. 21 shows an enlarged view of the air cleaner hose 6 where the permeable member 8 is attached on the hose 6 . For example, the permeable member 8 is integrally molded with the air cleaner hose 6 by insertion molding. The noise insulating wall 81 is attached to a noise insulating wall support member 90 formed on the hose 6 .
[0123] In addition, in the above embodiments, the single permeable member is disposed in the vicinity of the downstream of the air cleaner or the intake duct. However, a plurality of permeable members may be arranged in combination.
[0124] Further, in the above embodiments, the permeable member made of PET non-woven fabric is arranged. But, such permeable members are available as PP non-woven fabric, filter paper, or foaming resins as polyurethane foamed substance, polyethylene foamed substance, or polyvinylchloride foamed substance. In the third embodiment, if the air cleaner is mounted on the upper face of the cylinder head of the engine, the upper wall of the cylinder head may be utilized as the noise insulating wall. Then, the members are reduced in number.
[0125] In addition, the position, the number, or the shape of the communicating holes 530 are not especially limited in the noise insulating wall part 57 . Only, desirably, the communicating holes 530 are disposed at the side wall part of the noise insulating wall part 57 . The communicating holes 530 may be made by forming at the same time as the noise insulating wall part 53 , or may be made by boring process in the formed noise insulating wall part 57 .
[0126] It is preferable to determine the total air flow rate passing the communicating holes 530 to be larger than that passing the permeable member 54 . The noise insulating wall part 57 may be set at both of the dirty side case 50 and the clean side case 51 .
[0127] In addition, although the aforementioned various embodiments are explained independently, characteristics of each embodiment may be combined as freely as possible.
[0128] According to the invention, it is possible to offer the intake apparatus enabling miniaturization, to secure the desired engine output, and to suppress the noise. In accordance with the invention, it is possible to provide such an air cleaner, enabling to suppress not only air suction noise but also air transmitting noise and decrease the number of parts.
[0129] Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form can be changed in the details of construction and in the combination and arrangement of parts without departing from the spirit and the scope of the invention as hereinafter claimed.
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An air intake apparatus has an air intake port opening outside, and an air intake path communicating the air intake port with a combustion chamber of an engine. For suppressing noise getting out from the air intake port, with respect to walls partitioning the air intake path, an opening is provided at a part of said walls corresponding to an antinode region of resonance mode of standing wave in a full length of the intake path, or at a part of noise pressure level being high in the intake path. The opening is closed with a permeable member and a noise insulating wall is disposed outside the permeable member for suppressing emission of transmitting noise passing through the permeable member. member. Alternatively, a vibration control member for suppressing face-vibration of the permeable member and reducing radiant noise from the permeable member is provided instead of the noise insulating wall.
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This is a continuation of co-pending application Ser. No. 446,194, now abandoned, filed on Dec. 2, 1982, which is a continuation-in-part of U.S. Ser. No. 413,515, filed Aug. 31, 1982, now U.S. Pat. No. 4,468,847, issued Sept. 4, 1984.
BACKGROUND OF THE INVENTION
This invention relates to used containers fabricated at least in part from different metals or alloys, and more particularly, this invention relates to a method or process for reclamation of used containers, such as beverage containers, in a manner which permits recovery or segregation of container components substantially in accordance with their compositions, for example, or composition types.
In the packaging or container field, such as the used beverage containers having at least one or more components thereof fabricated from aluminum alloys, there has been ever-increasing interest and extensive research into methods of reclaiming the aluminum components. The interest has been precipitated by the importance of conserving resources and caring for environmental problems. However, heretofore recycling such materials has been greatly hampered by the lack of a method which would be economically attractive. For example, attempts to recycle a beverage can having a body fabricated from one aluminum alloy and a top or lid constructed from a different aluminum alloy often results in an aluminum melt having the composition of neither alloy. Such melt greatly decreases in value because it does not readily lend itself to reuse in the can body or lid without major dilutions, purifications and realloying or other modifications. That is, it can be seen that there is a great need for a method of recycling containers of the type, for example, described wherein the different components thereof are recovered and segregated according to alloy or according to alloy type.
The problem of segregation of different alloys is recognized in U.S. Pat. No. 3,736,896, where there is disclosed the separating of aluminum alloy tops or lids from steel bodied cans by melting a small band of aluminum around the periphery of the can body to provide a separating area allowing separation of the aluminum end from the steel cylindrical body. In this disclosure, induction heating is used to melt the band wherein an encircling inductor surrounds a bead and is connected to a high frequency power supply. However, this approach seems to presume that a used beverage can is not crushed and the end remains perfectly circular. Further, to melt the ends off in this manner would not seem to be economical since the ends would have to be removed individually.
In U.S. Pat. No. 4,016,003, containers having aluminum alloy bodies and lids are shredded to particles in the range of 1 to 11/2 inch and then subjected to temperatures of around 700° F. to remove paints and lacquers. In addition, U.S. Pat. No. 4,269,632 indicates that since the conventional alloys for can ends, e.g., Aluminum Association (AA alloy) 5182, 5082 or 5052, and for can bodies, e.g., AA3004 or AA3003, differ significantly in composition, and in the manufactured can, the end and body are essentially inseparable, and that an economical recycle system requires the use of the entire can. U.S. Pat. No. 4,269,632 further notes that the recycling of cans results in a melt composition which differs significantly from the compositions of both the conventional can end and can body alloys. In this patent, it is suggested that both can end and body be fabricated from the same alloy to obviate the recycling problem. With respect to can ends and bodies made from AA5182 and 3004, it is indicated that normally pure aluminum must be added regardless of the alloy prepared.
In view of these problems with recycling metal containers, such as aluminum beverage containers having components thereof comprised of different alloys, it would be advantageous to have a method which would permit recovery of the containers by segregating the components thereof according to their alloys or segregating the components according to their alloy type. That is, by segregation of the components prior to melting, the components can be melted and refabricated in accordance with normal procedures without, inter alia, expensive dilutions or purification steps.
SUMMARY OF THE INVENTION
An object of this inventicn is to provide a feedstock comprised of said metallic components, said alloys having different incipient melting tenperatures.
Another object of the present invention is to shred said feedstock and thereafter screen to remove fines therefrom having at least sizes in a size range of the fragment component.
Yet another object of the present invention is to heat the feedstock to effect incipient melting of the component having the lowest incipient melting temperature and agitate sufficiently to cause the component having the lowest incipient melting temperature to fragment.
And yet another object of the present invention is to segregate the fragmented components from the unfragmented feedstock.
These and other objects will become apparent from the drawings, specification and claims appended hereto.
In accordance with these objects, there is disclosed a method of detaching and segregating metallic components secured to metallic articles, the segregation being made in accordance with alloy composition of the components. The method comprises the steps of providing articles having at least two components thereon comprised of different aluminum alloys and heating the articles to a temperature sufficiently high to initiate incipient melting of the component having the lowest incipient melting temperature. While the articles are held at or slightly above the lowest incipient melting temperature of said aluminum alloy component, they are subjected to agitation sufficient to cause the aluminum alloy component having the lowest incipient melting temperature to fracture and detach itself from the article.
Thereafter, the fractured and detached components are segregated from the articles and recovered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow sheet illustrating steps which can be used in removing fines in a process for recycling used aluminum containers.
FIG. 2 is a bar graph showing the particle size distribution of material entering and exiting the furnace at a temperature of 1060° F.
FIG. 3 is a bar graph showing the particle size distribution of material entering and exiting the furnace at a temperature of 1080° F.
FIG. 4 is a bar graph showing the particle size distribution of material entering and exiting the furnace at a temperature of 1100° F.
FIG. 5 is a bar graph showing the particle size distribution of material entering and exiting the furnace at a temperature of 1120° F.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the flow sheet, used articles from which the aluminum alloy components are to be recovered or reclaimed may comprise containers such as food and beverage containers. Containers to which the process is suited are used beverage containers comprised of two different aluminum alloys. From the flow sheet, it will be noted that the articles to be recovered may be subjected to preliminary sorting to remove materials which would contaminate the aluminum alloy to be recovered. For example, it would be desirable to remove glass bottles and steel cans such as used for food, for example. Further, it is desirable to remove other materials such as dirt and sand, etc., in order to cut down on the amount of silicon, for example, that can occur in the reclaimed alloy. Elimination of these materials can permit use of the alloy reclaimed in accordance with the present invention without further purification procedures. The removal of steel preliminarily, as may be present in the form of containers or cans or other sources, aids in keeping the iron in the reclaimed alloy to a level which does not adversely affect the reclaimed alloy properties.
When the materials to be reclaimed are food or beverage containers, these are normally packaged in bales for shipping purposes and, therefore, prior to the sorting step, the bales would normally be broken apart to remove the foreign materials.
The bales may be subjected to a shredding type operation for purposes of breaking them apart. After the shredding operation, the feedstock should be screened for purposes of removing metal fines for purposes set forth in detail hereinbelow. As shown in FIG. 1, the fines may be subjected to a delacquering step and then recombined with a compatible fraction of the feedstock in accordance with the invention and eventually melted.
After the shredding and screening step, the shredded feedstock can be subjected to a delacquering step. This may be accomplished by solvent or thermal treatments. The delacquering removes the coatings, such as decorative and protective coatings, which can contain elements such as titanium which in high levels is not normally desirable in the aluminum alloys being reclaimed. When solvent delacquering is used, it is usually desirable to shred or pierce the containers in order to permit the solvent to drain therefrom. When the coatings are removed by thermal treatments, the temperature used is normally in the range of 600° to 1000° F.
In the next step of the process, particularly where the containers are used beverage containers having bodies formed from Aluminum Association alloy (AA) 3004 and having lids formed from AA5182, for example, the containers are heated to a temperature at which the AA5182 lid becomes fracture sensitive. This temperature has been found to correlate closely with the incipient melting or grain boundary melting temperature of the alloy.
Thus, in reference to used beverage containers, this is the incipient melting temperature of AA5182. By the use of incipient melting or grain boundary melting temperature herein is meant the lower temperatures of the melting range or phase melting range and slightly below at which the alloy develops or significantly increases in fracture sensitivity or at which fragmentation of the alloy can be made to occur without the use of great force. That is, in the fracture sensitive condition, fragmentation can be made to occur by the use of a tumbling action or falling action, and the use of forces such as would be obtained by a hammer mill or jaw crushers are not required. Forces such as encountered with a hammer mill or jaw crusher are detrimental to the instant process since they act to crush the containers, for example, thereby trapping material to be separated. It will be appreciated that many alloys have different incipient melting temperatures. For example, AA3004 has an incipient melting temperature of about 1165° F. and AA5182 has an incipient melting temperature of about 1077° F. and has a phase melting range of about 1077° F. to 1178° F. However, it will be appreciated that this range can vary depending to a large extent on the exact composition of the alloy used. Incipient or grain boundary melting of the alloy greatly reduces its strength and sets up the fracture condition. Thus, the AA5182 lids can be detached or removed from the AA3004 bodies because of the lids being provided in a condition which makes it highly sensitive to fracture and fragmentation. While in this condition, energy, e.g., tumbling action, can be applied for purposes of detaching or removing the lid from the can body. The detaching results primarily from the lid fracturing or fragmenting to provide lid particles which are not only smaller than the can body but generally smaller than a lid.
Thus, after the detaching step, there results a charge or mass comprised of can bodies and fragmented lids, the can bodies being comprised of an alloy or material different from the fragmented lids, the fragmented lids having a particle size distribution substantially different from the can bodies. Thus, it can be seen that not only is it important to remove the lid from the can body, but the lid fragments must have a particle size which is substantially different from the can body. For purposes of obtaining a product or alloy which is not adversely contaminated with the alloy with which it is commingled, the charge is subjected to a treatment for purposes of classifying or segregating the particles. When this aspect of the process is carried out, the result is lid fragments or values comprised of substantially the same alloys which are segregated from the can bodies.
While the process has been described in general terms with respect to reclamation of used beverage cans, it should be understood that the feedstock for the process is not necessarily limited thereto. That is, the process is capable of classifying aluminum alloys, particularly wrought alloys, where one of the alloys can be made fracture sensitive or put in a condition where one of the alloys can be fragmented preferentially in order to obtain a particle size distribution which is different from the particle sizes of the other alloys. In this way, a partition of the alloys can be made. Thus, for example, the feed stock for reclamation may be comprised of used beverage containers having bodies fabricated from AA3004 and lids fabricated from AA5182. Other alloys which may be used for lids include AA5082, 5052 and 5042 (Table X). However, other alloys which may be used for food or beverage can bodies include alloys such as AA3003, AA3104, AA5042 and AA5052 (Table IX). If such alloys are high in magnesium, for example, it is required that such can bodies be fractured or fragmented sufficiently to enable them to be classified with the lid alloys, such as AA5182. Thus, it will be understood that the process of the present invention is not only capable of removing and classifying lids from can bodies, as noted herein, but it is also capable of classifying the alloys in the can bodies with the lids when the alloys are of similar composition and which respond in a similar manner with respect to fracture or fragmentation characteristics, as explained herein.
In addition, where the containers have bodies and lids fabricated from the same alloy, that too may be reclaimed by classifying in accordance with the present invention. For example, if can body and lids are fabricated from sheet having the composition 0.1-1.0 wt. % Si, 0.01-0.9 wt. % Fe, 0.05-0.4 wt. % Cu, 0.4 to 1.0 wt. % Mn, 1.3-2.5 wt. % Mg and 0-0.2 wt. % Ti, the remainder aluminum, this would be classified in accordance with the invention. That is, if the feedstock to be reclaimed comprises used containers fabricated from mixed alloys such as 3004, 5182, 5042, as well as the can body and lid alloy above, this alloy would be expected to be classified with the AA3004 body stock because no incipient melting would occur when the temperature was sufficiently high to cause fracture of AA5182 or AA5042.
Likewise, if steel containers having 5182 lid attached thereto are present in the feedstock, the lids can be classified in accordance with the invention and the steel bodies would be recovered with 3004 can bodies. The steel container bodies can be separated from the aluminum alloys with which they may be classified by magnetic separation means, for example, after the lids have been removed. If the steel bodied containers had lids which fractured at temperatures in the AA3004 incipient melting range, then it would be necessary to heat the containers to a higher temperature as compared to AA5182 to effect a separation of the lid from the steel body after which the steel bodies could be removed by magnetic separation, for example.
From the above, it will be seen that the process of the present invention is rather insensitive to the aluminum feedstock being recovered. That is, the process is capable of handling most types of aluminum alloys and is particularly suited to recovering and classifying wrought alloy products such as is encountered in used containers. If the scrap were comprised of aluminum alloys used in automobiles, for example, AA6009 and AA6010, as described in U.S. Pat. No. 4,082,578 herein incorporated by reference, where the use can be hoods and doors, etc., it may be desirable to subject such articles to a shredding action to provide a generally flowable mass. Or in recovering AA2036 and AA5182 from used automobiles, it may be desirable to shred such products and then effect a separation, as noted herein.
With respect to grain boundary melting or incipient melting of one of the aluminum alloy components to effect fracture sensitivity or fragmentation, it will be understood that this is an important step of the process and must be carried out with a certain amount of care. Using the used beverage cans as an example again, it will be noted that temperature control is important in this step. That is, if the temperature is permitted to get too high, substantial melting of the AA5182 lid can occur, which can result in losses with respect to aluminum and magnesium because of oxidation. Temperatures which bring about substantial melting of the metal normally should be avoided for the additional reason that it can result in coagulation of particles with molten aluminum to form a mass which is not readily flowable when compared to finer discrete particles. Further, molten aluminum can stick to the furnace and start building a layer of metal and particles therein which, of course, interferes with the efficiencies of the whole operation. Also, classification of the congealed mass becomes much more difficult, if not impossible. Lastly, on melting, fines such as sand, glass, dirt and pigments or contaminants such as silicon oxide, titanium oxide and iron oxide tend to become embedded in the molten metal, further making separation thereof difficult. Thus, in view of the above, it can be seen why temperatures which result in substantial melting of one of the aluminum alloy components should be avoided.
Likewise, when temperatures are employed which are too low, the fracture sensitivity of the lids drop dramatically and resistance to fragmentation increases substantially with the result that separation becomes extremely difficult and often segregation cannot be effected. Accordingly, it will be seen that it is important to have the temperature sufficiently hlgh in order to remove the lid from the can body. For lids formed from AA5182, this temperature correlates to about the incipient melting temperature which is about 1077° F. The melting range for AA5182 is about 1077° to 1178° F. Thus, if the used beverage containers are heated to 1100° F., this is well below the melting range of AA3004 (about 1165°-1210° F.) and the lids can be detached or removed without fracturing the can bodies.
With respect to grain boundary or incipient melting, it will be understood that because the sheet from which the lids are fabricated has been rolled to a thin gauge, grains are not well defined. However, it is believed that recrystallization occurs when the used beverage containers are heated, for example, to remove lacquer, which can occur at 850° F., for example. Thus, grain boundary melting can occur.
When the used beverage containers were heated to about or slightly above 1100° F., generally it was found that the AA5182 ends sagged or slumped on the AA3004 can body. However, when the containers were agitated at about this temperature by permitting them to drop from a conveyor belt, for example, the lids were found to detach themselves from the can bodies and were divided or fragmented in small particles while the can bodies were relatively unchanged. Agitation sufficient to detach the ends also may be effected in a rotary furnace or kiln while the used cans are heated to a temperature in the range of 1077° to about 1155° F., with a preferred range being 1077° to 1130° F. and typically not higher than 1120° F. Agitation sufficient to remove the ends in the rotary furnace can be that which occurs at these temperatures when the cans are tumbled inside the furnace. As noted hereinabove, forces such as obtained from hammering or by the use of jaw crushers should not be used because they act to flatten the cans or otherwise entrap the fragmented ends with the can bodies. As noted earlier, operating at temperatures high in the melting range can result in too much liquid metal and the attendant problems therewith. The melting problem becomes particularly acute if the used beverage cans are held for a relatively long time at temperatures high in the melting range. At temperatures in the range of 1077° to 1130° F., the time at temperature can range from 30 seconds to less than 10 minutes.
In the classification step, the AA5182 fragments can be separated from whole can bodies or from can bodies which have been shredded by screening. However, it will be appreciated that other methods of separation may be used, all of which are contemplated to be within the purview of the present invention.
In another aspect of the invention, it has been found important to remove metal fines from the process. That is, when it is found desirable to shred the aluminum articles, e.g., used aluminum materials such as used containers, it has been found that shredding results in the generation of a significant amount of fine metal referred to herein as fines. Normally, the generation of such fines would not be considered to be a significant problem. However, when beverage containers are processed to separate the lids from the container bodies, the lids are fragmented as noted herein, and have a size range substantially smaller than the bodies which permit separation therefrom. However, if the used materials, e.g., used beverage containers, are shredded prior to processing for separation purposes, the shredding can result in fines which are in the size range constituting the lid fragments. The fines generated by shredding, in fact, can be said to contaminate the fragmented portion. For example, if the beverage can is constituted of 75 wt. % AA3004 and 25 wt. % AA5182, the fines generated on shredding a feedstock comprised of such containers can have 93 wt. % of AA3004 and only 7 wt. % AA5182. Thus, it will be seen that there is a great need to prevent this type of contamination in the present process. Omitting the step of removing the fines results then in the fragmented AA5182 portion being contaminated with AA3004 fines from the can bodies. Thus, it has been found that removing fines in the size range corresponding to the size range of the fragmented portion being separated from the container body portion results in substantially fragmented portions being substantially free of fines. The fines should be removed after the shredding step and before fragmenting step. One method of removing the fines can be the use of screens, although other techniques, such as air separation and the like, are contemplated within the purview of the invention.
When the feedstock used is beverage containers having, for example, AA3004 bodies and AA5182 lids, after shredding, the fines can constitute 1 to 15 wt. % or more of the shredded feedstock.
In a test utilizing whole cans, the used beverage containers were processed in a test apparatus at about 1110° F. The fragmented end pieces were 25.3% of the delacquered can weight. The body parts represented 74.7%. This suggests that the alloy separation was nearly 100% effective. The two portions were melted and analyzed. The spectrographic results appear in Table VIII which may be compared to AA5182 and AA3004 (See Tables IX and X). These analyses further support that 100% separation of the two alloys is possible when the starting material is whole cans.
The following provides an example of the contamination which can result from the fines generated by shredding. From Table X, the composition range for manganese in AA5182 is 0.20 to 0.50 wt. %. Normally, manufacturers of AA5182 maintain the manganese composition near the middle of this range. For purposes of the following examples, it is to be assumed that manganese concentration of 0.38% is desired.
If the process of shredding and subsequent fragmentation is performed on 100 units of used beverage containers, it has been found in one instance that five units of fines generated in the shredding step had a manganese level of 1.10%. These are, therefore, composed almost entirely of AA3004. The fragmentation step produced 20 units of AA5182 with a manganese level of 0.38%. If these 25 units are not separated but are collected together, then the resulting manganese level can be calculated to be 0.52%. This requires significant dilution to produce metal of 0.38% manganese.
In yet another example, if the process produces a shredded product or feedstock that contains approximately 9 wt. % fines, the manganese level of this material is 1.05 wt. %. If these 9 units were collected in the fragmented portion together with the 20 units of AA5182, the total 29 units would have a manganese level of 0.59 wt. %. Again, this requires significant dilution with pure aluminum to produce AA5182 having a manganese level of 0.38 wt. %. Thus, it can be seen that it is important to remove the fines prior to their being commingled with the fragmented portion.
As further illustrative of the invention, used beverage cans having AA3004 bodies and AA5182 lids thereon were processed through a rotary-type kiln. Samples were taken of ingoing and exiting material for the rotary kiln at four different kiln set temperatures, as follows: 1060°, 1080°, 1100° and 1120° F. Ingoing samples were taken which weighed about 15 kg (35 lb). Approximately six minutes later, representing the residence time of used beverage cans in the kiln, about 45 kg (100 lb) of exiting material was sampled.
Prior to entering the furnaces, bales of used beverage cans were processed through a shredder. The shredder in the process of partially shredding most of the cans, generates some used beverage can fines. In the figures, the screen analyses of ingoing and exiting material are compared at each kiln set temperature to determine the degree to which end fragmentation occurs inside the kiln. This is recognized as a decrease in weight of the coarser fractions and an increase in weight of the finer fractions.
The U.S. Standard Screen sizes that were used to fractionate the samples are listed in Table I, together with the Tyler mesh equivalents.
Samples of each size fraction were melted and analyzed to monitor alloy partitioning and also to measure the amount of tramp impurity pickup.
The chemical composition of a sample makes it possible to calculate the relative amount of AA3004 and AA5182 present. This is done by assuming that AA3004 contains 1.10% manganese and that AA5182 contains 0.38% manganese. A melt of used beverage cans having a manganese content of 0.92% can be shown to contain 75% of AA3004 material and 25% of AA5182 material. This calculation was done for each exiting fraction at the four kiln temperatures of the test. The amount of AA5182 calculated to be present appears as the totally shaded portion on the bar graphs in FIGS. 2-5.
FIG. 2 shows the particle size distribution of ingoing and exiting material while the kiln set temperature was 1060° F. The distribution of AA5182 in the exiting material is also shown. The recorded temperature during the sampling period ranged from 1030° to 1060° F. The primary feature in the figure is that very little difference is seen in the size distribution of ingoing and exiting material. It is also shown that the mix of AA5182 and AA3004 in the coarser exiting fractions is approximately 25% and 75%, respectively, which indicates that lid fragmentation did not appear to be occurring at this temperature.
Table II shows the spectrographic analysis of the metal found in each size fraction for both entering and exiting material. Again, ingoing and exiting material for a given size fraction appear to be very similar, except for magnesium.
There does, however, appear to be a variation in composition that is dependent on size fraction which suggests that the crushing step, prior to delacquering, generates more body fines than end fines. The finer fractions exhibit elevated manganese levels and decreased magnesium levels when compared to the coarser fractions. These finer fractions, therefore, appear to be richer in AA3004 content than the coarser ones. With the can body being thinner and accounting for a larger surface area of the can than the end, it may be experted that in shredding used beverage cans the body would produce more fines than would the end. The decreasing magnesium content with finer particle size may also reflect the increased magnesium oxidation incurred when melting the smaller sized material for analysis purposes. The -10 mesh material, both ingoing and exiting, did not contain sufficient metallic material to melt and produce a sample for spectrographic analysis.
The data from samples taken while the kiln set temperature was 1080° F. and 1100° F. appear in FIGS. 3 and 4 and Tables III and IV, respectively. These samples show fragmentation of AA5182 lids inside the rotary kiln. Specifically, the amount of material present in the finer mesh fractions in the exiting material is increased when compared to the ingoing material; and these fines have compositions that show AA5182 enrichment. This trend is more pronounced at 1100° than at 1080° F.
The samples taken at 1120° F. show the strongest, definitive evidence for AA5182 fragmentation inside the kiln. The two coarsest fractions have experienced a significant weight reduction after passing through the kiln and the four finer fractions all show a significant weight increase (FIG. 5). The compositions of the fractions (Table V) show that the coarser fractions are nearly commercial grade composition of AA3004 and that the finer material is nearly the commercial grade composition of AA5182. Comparing data for the 1060° F. and 1120° F. experiments shows migration of AA5182 from the coarse fractions to the fine fractions.
Table V shows that metal from the -10 mesh fraction of the 1120° F. sample contains 0.50% silicon. This is very significant since this fraction represents approximately 30% of the AA5182 in the system. This material was further screened down to determine the possibility of screening out the tramp silicon contaminants. The results appear in Table VI. The tramp silicon apparently migrates to the -20 mesh fractions. The -25 mesh fraction contained such a large amount of non-metallic material that it could not be melted to prepare a sample for spectrographic analysis. Visual inspection revealed significant quantities of glass and sand. Chemical analysis of the -25 material appears in Table VII. This fraction contains only about 56% metallic aluminum. The sand and glass content is about 23 wt. %, and the tramp iron content about 1.7 wt. %. Discarding all -20 mesh material, to minimize tramp silicon and iron pickup, will contribute 2.2% to the system loss. However, this material contributes substantially to skim generation and should be removed prior to melting for this reason.
TABLE I______________________________________Screens Used to Fractionate the SamplesU.S. Standard Tyler MeshScreen Equivalent______________________________________2 inches 2 inches1 inch 1 inch0.5 inch 0.5 inch0.265 inch 3 meshNo. 4 4 meshNo. 7 7 meshNo. 10 9 meshNo. 14 12 meshNo. 18 16 meshNo. 20 20 meshNo. 25 24 mesh______________________________________
TABLE II______________________________________Chemical Analyses of Ingoing (IN) and Exiting (OUT) MaterialFor Each Size Fraction. Kiln Set Temperature: 1060° F.U.S.Screen Si Fe Cu Mn Mg______________________________________+2"IN .17 .41 .11 .90 1.19OUT .17 .41 .11 .91 1.23-2" + 1"IN .17 .41 .11 .92 1.22OUT .18 .40 .10 .86 1.20-1" + 1/2"IN .16 .38 .10 .85 1.72OUT .16 .39 .11 .86 1.02-1/2" + 0.265"IN .17 .41 .11 .91 1.19OUT .17 .40 .11 .92 .78-0.265" + 4IN .21 .41 .12 1.00 .73OUT .24 .42 .12 1.01 .78-4 + 7IN .37 .45 .14 1.06 .35OUT .26 .45 .13 1.05 .68-7 + 10IN .24 .44 .13 1.06 .26OUT .24 .48 .13 1.03 .54-10*IN -- -- -- -- --OUT -- -- -- --______________________________________ *Contained insufficient metal content for quantometer analysis.
TABLE III______________________________________Chemical Analyses of Size Fractions Exitingthe Kiln at a Set Temperature: 1080° F.U.S.Screen Si Fe Cu Mn Mg______________________________________+2" .17 .39 .11 .95 .96-2" + 1" .18 .39 .10 .91 1.05-1" + 1/2" .17 .39 .11 .90 1.10-1/2" + 0.265" .17 .39 .10 .87 1.03-0.265" + 4 .22 .38 .10 .83 1.63-4 + 7 .18 .36 .09 .73 2.08-7 + 10 .17 .32 .07 .60 2.70-10 .23 .32 .11 .55 1.54______________________________________
TABLE IV______________________________________Chemical Analyses of Size Fractions Exitingthe Kiln at a Set Temperature: 1100° F.U.S.Screen Si Fe Cu Mn Mg______________________________________+2" .17 .41 .12 .94 .48-2" + 1" .18 .42 .12 .97 .66-1" + 1/2" .19 .42 .12 .98 .64-1/2" + 0.265" .18 .41 .12 .94 .56-0.265" + 4 .17 .35 .09 .73 1.36-4 + 7 .15 .30 .19 .56 2.57-7 + 10 .15 .29 .06 .46 2.15-10* -- -- -- -- --______________________________________
TABLE V______________________________________Chemical Analyses of Size Fractions Exitingthe Kiln at a Set Temperature: 1120° F.U.S.Screen Si Fe Cu Mn Mg______________________________________+2" .19 .44 .13 1.05 .58-2" + 1" .18 .43 .12 1.02 .66-1" + 1/2" .18 .44 .12 1.03 .67-1/2" + 0.265" .18 .43 .12 1.02 .57-0.265" + 4 .21 .37 .10 .82 1.61-4 + 7 .17 .30 .07 .52 2.97-7 + 10 .18 .25 .05 .36 3.43-10 .50 .29 .07 .36 3.35______________________________________
TABLE VI______________________________________Chemical Analyses of Fractions Resulting FromFurther Fractionation of the Minus 10 MaterialExiting the Kiln at Set Temperature 1120° F.U.S.Screen wt. % Si Fe Cu Mn Mg______________________________________-10 + 14 2.6 .15 .27 .04 .38 3.67-14 + 18 1.9 .16 .28 .04 .38 3.82-18 + 20 0.5 .21 .26 .04 .35 3.64-20 + 25 0.4 .35 .21 .05 .33 3.74-25* 1.8 -- -- -- -- --______________________________________ *Contained insufficient metal content for quantometer analysis.
TABLE VII______________________________________Analysis of Minus 25 Material Exitingthe Kiln at a Set Temperature: 1120° F.______________________________________% Aluminum by Hydrogen Evolution 56.2%Chemical Analysis: Al 56.7%Fe 1.74%Si 10.8%Calculated SiO.sub.2 23.1%% Magnetic Material 1.87%X-ray Diffraction: Aluminum 10%Quartz 10%MgO 10%Unidentified 10%______________________________________
TABLE VIII______________________________________Chemical Analyses from Whole Can ExperimentHaving 3004 Bodies and 5182 Ends End Fragments Body Parts______________________________________Si 0.10 0.19Fe .25 .40Cu .03 .14Mn .36 1.09Mg 3.69 .7Cr .02 .01Ni .00 .00Zn .02 .04Ti .01 .02______________________________________
TABLE IX__________________________________________________________________________ OthersAlloySilicon Iron Copper Manganese Magnesium Chromium Zinc Titanium Each Total__________________________________________________________________________AA30030.6 0.7 0.05-0.2 1.0-1.5 -- -- 0.10 -- 0.05 0.15AA3004 0.30 0.70 0.25 1.0-1.5 0.8-1.3 -- 0.25 -- 0.05 0.15AA31040.6 0.8 0.05-0.25 0.8-1.4 0.1-1.3 -- 0.25 0.10 0.05 0.15__________________________________________________________________________ Note: In Table IX, the balance is aluminum, and composition is in wt. % max. unless shown as a range.
TABLE X__________________________________________________________________________ OthersAlloySilicon Iron Copper Manganese Magnesium Chromium Zinc Titanium Each Total__________________________________________________________________________AA51820.20 0.35 0.15 0.20-0.50 4.0-5.0 0.10 0.25 0.10 0.05 0.15AA50820.02 0.35 0.15 0.15 4.0-5.0 0.15 0.25 0.10 0.05 0.15AA50520.45 Si + Fe 0.10 0.10 2.2-2.8 0.15-0.35 0.10 -- 0.05 0.15AA50420.20 0.35 0.15 0.20-0.50 3.0-4.0 0.10 0.25 0.10 0.05 0.15__________________________________________________________________________ Note: In Table X, the balance is aluminum, and composition is in wt. % max. unless shown as a range.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass other embodiments which fall within the spirit of the invention.
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In a process of fragmenting and segregating shredded metallic components fabricated from different aluminum alloys in which a fragmented component is provided, a method of removing fines for purposes of enhancing segregation of the alloys, the method comprising the steps of providing a feedstock comprised of said metallic components, said alloys having different incipient melting temperatures, the feedstock is shredded and thereafter screened to remove fines therefrom having at least sizes in a size range of the fragment component. The feedstock is heated to effect incipient melting of the component having the lowest incipient melting temperature and agitated sufficiently to cause the component having the lowest incipient melting temperature to fragment. The fragmented components are segregated from the unfragmented feedstock.
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BACKGROUND OF THE INVENTION
This invention regards a device for controlling the feeding of metal bars that have to be taken, through a proper guide equipment, to a multiple-spindle lathe.
In the aforesaid kind of lathes, unlike single-spindle lathes, succeding machining operations on workpieces are carried out, as it is known, by taking the workpieces sequentially to the tools or tool assemblies making up each working station. Therefore, in a multiple-spindle lathe the spindles are held by a fundamentally circular rotating drum, on which the spindles are at the same distance between one another, arranged angularly along a circumference.
These lathes are fed through appropriate guide equipment that is placed adjacent the lathe and consists basically of a series of tubular guides. The latter, too, are situated along a circumference, on the same longitudinal axis as the lathe spindles, and they are held by a turning frame that rotates synchronously with the spindle-holding drum.
The device that is the object of this invention is meant for the control of the feed of metal bars through the aforesaid guide equipment to the lathe, particularly into its spindles.
The brief description herein made of a multiple-spindle lathe and of guide equipment aims only at making this specification more complete and the features of this invention better understandable. In fact, the lathe and the guide equipment are not the object of this invention.
Finally, for a better comprehension of how the invention works, it is to be noted that the bar feed is not steady, but the bars jog and are fed according to the length required to make a new piece.
There are several devices for controlling the feed of bars to a multiple-spindle lathe as specified hereinbefore.
In a first type of these devices the bar-pushers to push bars into the guides are driven by only one drive motor, which turns a series of shafts, arranged on a drum substantially in a star-like manner, by means of a system of bevel gear pairs. The aforesaid drum rotates synchronously with the lathe drum. A pulley is splined to each shaft, and a steel-wire rope, to which a bar-pusher is fixed, is wound around this pulley. When the spindles stop the bars, there is the friction slip of the steel-wire ropes on the pulleys of the various shafts, since the bar cannot be fed any more. This leads to a high degree of wear concerning both the pulleys and the steel-wire ropes.
Another negative aspect of this device is that all ropes shall always be perfectly stretched in order to avoid sliding, which would prevent the bar from being fed, when the corresponding spindle is opened to allow the traverse of the former. That could bring about insufficient feeding, i.e. a length is fed that is less than that of the piece to be made, or even no feeding takes place. Therefore, besides the disadvantages first above described, the above mentioned device cannot be relied upon and requires steady maintenance, which implies that the lathe shall be inoperative for remarkable spans of time. That is extremely negative taking into account that the best output of a multiple-spindle lathe can be got only by minimizing its downtime.
Another known device is provided with a series of feed shafts arranged so as to resemble a star on a rotating drum. Each shaft is furnished with ts own motor reducer with clutch, which is operated whenever the corresponding bar has to be fed. This kind of device is extremely difficult to be built both because of the need of various drive motors and owing to the uneasy power supply of these motors applied to a turning drum. It goes without saying that the electric systems of these devices turn out to be complicated and prone to failures, which compel to stop the lathe, thus reducing its output rate as defined hereinbefore.
Both types of above mentioned devices are characterized also by the common disadvantage that they can be used only for one type of lathe, namely that where the spindle centre distance is the same as the centre distance of the bar feed controlling devices. It means that they cannot be used for a lathe where the spindle distance from the rotation centre of the drum is different from the distance of the pulleys or of the gears of the motor reducers from the rotation centre of their drum. This leads to the need of building a specific bar feed device for each lathe with a certain centre distance, as first above defined.
The disadvantages so far mentioned can be eliminated thanks to the subject of this invention, i.e. a device for controlling the feeding of metal bars to a multiple-spindle lathe.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and the advantages of the device according to this invention can be found in the following detailed description of a non limiting embodiment of the device itself, made with reference to the attached figures, of which;
FIG. 1 is a front view of the device on the side opposite to that where the metal bar guide equipment is situated;
FIG. 2 is a view of the device on the same side as FIG. 1, where a front plate is lacking in order to show its middle cross section;
FIG. 3 is a view of the device as per section III--III of FIG. 1;
FIG. 4 is a view of the device as per section IV--IV of FIG. 1;
FIGS. 4a and 4b are an enlarged representation of sections V--V and VI--VI of FIG. 4;
FIGS. 5 and 6 are a front view and a cross section view of a first modification of the device subject of this invention; and
FIGS. 7 and 8 are a front view and a cross section view of a second modification of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference at first to FIGS. 1 through 4 the first embodiment of the device object of this invention will be described.
However, it is to be defined before the position of the device as against the metal bar guide equipment and the lathe. The device is situated at the rear end of the metal bar guide equipment, and (see FIG. 4) this equipment and the lathe are series-connected to each other on the left side of the device, as shown in FIG. 4. The views of FIGS. 1 and 2 are to be seen as per the sense of arrow F in FIG. 4.
The device object of this invention includes a driving unit 1, consisting of a motor reducer with clutch of known type, to shaft 2 of which a gear 3 is splined, that is connected, through a chain 4 schematically shown with a chain line, to a gear 5 splined to a shaft 6. Shaft 6 is partially situated inside a basically cylinder-shaped body or drum 7, the main parts of which are a first flange 8, which can be considered as the rear flange since it is placed on the side opposite to the bar guide equipment, and a front flange 9 which are integral with each other in any known way, not shown herein. Drum 7 is made integral with the bar guide equipment, exactly with the drum of the guide equipment which makes the bar guides turn, therefore drum 7 rotates synchronously with the aforesaid equipment and consequently with the lathe spindle drum.
In a basically central part of device drive shaft 6 there is a circular radial projecting part 10 that can rotate freely in a seat 11, made on the inner face of rear flange 8.
Corresponding to projecting part 10 of shaft 6 there is a ball bearing 12, which allow the free turning of shaft 6 as against drum 7.
A circular crown gear 14 with fundamentally front teeth is fixed on radial projecting part 10 of shaft 6: this crown gear rotates together with shaft 6.
A sleeve body 15 is situated on the same axis as shaft 6, at the end opposite to that on which gear 5 is splined; sleeve body 15 is fixed to front flange 9 through locking screws 16. At its end inside drum 7 sleeve body 15 acts as a support of shaft 6 through ball bearing 17. Shaft 6 is supported by drum 7 and by sleeve body 15 through oilless bushings 18 and 19.
Inside drum 7, around sleeve body 15, the control units are disposed, which are situated radially in a star-like manner. Each of these units is indicated by the numeral 20 and controls the feed of a metal bar, when it is operated, that is connected to shaft 6.
Only one of control units 20 will be described, since they are all identical. In the embodiment shown of the device which is the object of this invention the control units are six in number, because the device is supposed to be used for a six-spindle lathe, but it goes without saying that there is no limit to their number.
Here follows the description of control unit 20 that is situated in the upper part of FIG. 4. The unit is working, i.e. it is controlling the feed of its corresponding bar, as will turn out to be clearer in this specification.
Control unit 20 includes a longitudinally hollow shaft 21, the lower end of which is situated in an appropriate seat 22 of sleeve body 15 in an oilless bushing 23. Corresponding to the lower end of hollow shaft 21, there is a bevel gear 24, which has the same axis as shaft 21. Bevel gear 24 is always in mesh with circular crown gear 14, therefore it is always turning. Bevel gear 24 has an upper cylindrical extension 25, and between the latter and shaft 21 there is an oilless bushing 26. Over gear 24 shaft 21 is provided with a radial projecting part 27 to keep gear 24 in the position in which it is in mesh with circular crown gear 14.
The upper end of shaft 21 is inserted in a unit 28 that allows the shaft to turn through the mechanisms hereinafter described, when it is operated, as explained in the following part of the description, in order to control the feed of a bar.
Unit 28 includes a fundamentally cylindrical outer flange 29, a circular middle flange 30 and an annular inner flange 31. These three flanges are fixed to one another through locking screws 32, and inner flange 31 shall be fixed also to drum 7 in any known way.
Middle flange 30 is provided with a substantially cylindrical, longitudinal passage and with ball bearing 33, placed in its appropriate seats, that, together with an oilless bushing 34, account for the turning of shaft 21.
The longitudinal part of shaft 21, from the lower edge of inner flange 31 to its radial projecting part 27, has a series of fundamentally longitudinal ribs 35, which can be better seen in FIG. 2; these ribs are situated all around the side surface of the shaft. A gear 36 is mounted on this part of shaft 21, and gear 36 has a cylindrical part 37, which is furnished with a radial passage 38 to insert a locking screw or security dowel 38a. Gear 36 and its cylindrical part 37 have some grooves on their inner surfaces, grooves that correspond to the shape of ribs 35 of shaft 21, so that gear 36 can be moved along shaft 21 and locked in the desired position through dowel 38a. In this way gear 36, around which the chain controlling the bar-pusher is wound, can be moved and adjusted according to the centre distance of the guides, i.e. according to the lathe spindle centre distance. Gear 36 is thus adapted to provide the motive power for the drive chain of an automatic feeder for a multiple spindle machine such, for example, as is shown in U.S. Pat. No. 3,874,519.
Inside hollow shaft 21 there is a sliding pin 39 which is engaged, through its biggest part 40, with a spring 41, the other end of which is engaged with a step-shaped inner projecting part 42 of shaft 21. Spring 41 is under pressure, so that it pushes pin 39 towards the outside of shaft 21, or more precisely towards the outside of drum 7. During the assembly of the device, pin 39, and particularly its biggest part 40, abuts against a bushing 41a screwed on the upper end of shaft 21. This bush is meant to prevent pin 39 of shaft 21 from coming out.
Upper end 42 of pin 39 is engaged through a thrust bearing 43, with an element 44 on which a wheel 46 is mounted on a pin 45 in such a way that it can turn. Element 44 can be longitudinally moved in a slit in a cylindrical part 47, projecting over upper flange 29. In this way element 44, and therefore wheel 46, move together with pin 39, sliding inside hollow shaft 21.
As it appears from FIG. 4, pin 39 has a zone or segment with a smaller diameter 48 near its lower end. The ends of this zone are radiused to the rest of pin 39. Therefore the latter, through the two flared parts connecting the cylindrical part with a greater diameter to the cylindrical part with a smaller diameter, shows a reduced-diameter zone, the function of which is described in the following.
When pin 39 is moved radially towards the inside of drum 7, reduced diameter zone 48 is engaged with a pawl or mobile key 49, which is the mobile part for connecting and disconnecting shaft 21 from gear 24.
In the embodiment shown, only one mobile key 49 is scheduled, but it goes without saying that more than one mobile key (e.g. two or three) can be scheduled, which have to be distributed evenly around pin 39. Of course, the diameters of pin 39 and of smaller-diameter zone 48 shall be of such a value as to avoid any interference among the mobile keys.
With reference now to FIGS. 4a and 4b, which show a cross section of shaft 21 in correspondance of pawl 49, it is described how aforesaid mobile key 49 engages or disengages reciprocally shaft 21 and gear 24.
The two conditions mentioned just now can be seen in FIG. 4 respectively for the upper control unit, which is working, and for lower control unit 20, which is not working. FIGS. 4a and 4b are cross sections, showing the same conditions.
When a control unit is working, as is upper control unit 20 shown in FIG. 4a (cross section), key 49 is engaged basically with the lower end of pin 39, i.e. outside its smaller diameter part 48. In such position key 49, particularly its part 49a which is basically cylindrical, is inserted in a corresponding recess, that, too, consists of a semi-cylindrical wall 24a of the inner wall of the passage of gear 24, through which shaft 21 is inserted. Therefore key 49 is made to turn by gear 24 and transmits such movement to shaft 21.
As can best be seen in FIGS. 4a and 4b, the wall of the axial passage of gear 24 shows a series of recesses 24a, each consisting of a sector of fundamentally cylindrical wall; these recesses are connected to one another by means of chamfered ribs 24b.
When the condition of pin 39 is changed from that shown in FIG. 4a into that in FIG. 4b, mobile key 49 is engaged with smaller-diameter part 48 of pin 39. As a consequence of the rotation of gear 24 mobile key 49 is moved radially towards pin 39, disengaging itself from recess 24a where it was. This movement is brought about by ribs 24b, which, by acting on semi-cylindrical wall 49a of mobile key 49, push the latter radially towards the inside of shaft 21. This movement is possible since mobile key 49 does not hinder it in any way, because it is in contact with smaller-diameter part 48 of pin 39. In this condition, when mobile key 49 is disengaged from gear 24, the rotation movement of the latter is no longer transmitted to shaft 21, which consequently stops turning.
It is also to be stressed that it is spring 41 that accounts for the radial movement towards the outside of drum 7 of pin 39. That is important since the coupling of mobile key or keys 49 with one or more recesses 24a of gear 24 is carried out elastically, thus preventing the device from binding.
Also the shape of the part of mobile key 49 that engages itself with pin 39 is noteworthy; it can be seen in details in the enlarged particular, outside FIG. 4b. The part just mentioned of mobile key 49, part that is characterized by symbol 49b and a side view of which can be found in FIGS. 4a and 4b, is fundamentally semi-circular, but it has no sharp edge: on the contrary, it is saddle-shaped, i.e. its concave central part which engages itself with pin 39 is flared on both sides towards end 49a. The mobile contact between key 49 and pin 39 is kept stable and unbound thanks to the aforesaid shape, together with the flared segment connecting part 48 of pin 39 to the rest of the pin itself.
A basically ring-shaped cam 54 accounts for the movement required to take pin 39 from the position in which mobile key 49 engages itself with its greater-diameter part (shaft 21 turning) into that in which the key engages itself with small-diameter part 48 of pin 39 (shaft 21 not turning) and for the reverse movement as well. Cam 54 is fixed to a base, not shown, and is basically on the same axis as drum 7, as as can be seen in FIGS. 1 and 2.
In the embodiment shown, cam 54 is provided with a recess 55 on its inner face, allowing pin 39, thanks to spring 41, to move towards the outside of drum 7, so that mobile key 49 can disengages itself from smaller-diameter part 48 of pin 39 and can engage itself with its greater-diameter part, thus keeping bevel gear 24 turning with shaft 21. In such a way control unit 20, wheel 46 of which moves in recess 55, is operated and the corresponding bar-pusher pushes the length of bar required forward.
When the aforesaid unit has gone beyond recess 55, thus returning in the steady-diameter part of cam 54, pin 39 is made to go back into hollow shaft 21, and mobile key 49, engaging itself with smaller-diameter part 48 of pin 39 again, comes out of recess 24a of gear 24, thus disengaging gear 24 from shaft 21, which is not working now.
In the embodiment shown, cam 54 has just one recess 55, which means that six control units 20 are operated one by one. However, it goes without saying that more recesses 55 can be scheduled, which will be properly offset in order to operate more than one control unit 20 simultaneously.
To secure it to its fixed base (not shown in the picture), cam 54 is furnished with slots 56, meant for its adjustment.
Particularly in FIG. 2 it can see that, corresponding to gears 36, which transmit movement to the bar-pushers, there are some slits 57 on front flange 9. These slits are basically parallel to shaft 21 and fundamentally as long as ribs 35. So, when gears 36 are moved so as to adjust their centre distance to that of the metal bar guides, the movement transmitting chains are moved correspondingly in slits 57, thus permitting to adjust the device of this invention according to the lathe centre distance, no matter what value it may be.
FIGS. 5 and 6 show another embodiment of the device of this invention, namely in FIG. 5 this embodiment is illustrated in the same view as in FIGS. 1 and 2, i.e. from the rear side of the device, while FIG. 6 is a view according to section VI--VI of FIG. 5.
The embodiment shown in the aforesaid figures consists mainly of a more sophisticated device than that in FIGS. 1 through 4, namely of a device allowing simultaneous and independent control of two bar-pushers and to get two different-length feeds by adjusting and properly positioning the known bar feed stops in the lathe.
In FIGS. 5 and 6 the same elements as in FIGS. 1 through 4 are characterized by the same reference numbers.
This embodiment accounts for the simultaneous reverse movement of two bar-pushers as well.
In this case the device includes two oleodynamic-type control units 60 and 61 with clutch, each of which is connected through chains 62 and 63 respectively to gears 64 and 65 splined to shafts 66 and 67 having the same axis and able to turn independently of ach other. Shaft 66, i.e. the inner one, is longer and projects outside shaft 67 as against drum 7. Both shafts 66 and 67 are supported in the known way by oilless bushings 68 and 69, placed between them and the supporting walls of a box element 70, situated and fixed inside drum 7. The box element 70 allows to apply a kinematic mechanism to transmit motion from shaft 66 and 67 to different control units 20.
Splined shafts 21 are supported not only by drum 7, but also by box element 70, they cross its side wall and are supported by bearings 71, allowing them to turn.
The part of shafts 21 inside box element 70 is provided with a pair of annular gears 72 and 73, the shape of the inner longitudinal passage of which is basically the same as that of bevel gear 24 in the first embodiment for the control of the movement of mobile key 49. Therefore, even if not shown, this passage is so shaped as shown in FIGS. 4a and 4b.
There are four mobile keys 49 for each pin 39 and they are situated in appropriate passages in splined shaft 21 in such a way that two keys are opposite to the other two. Smaller-diameter part 48 of pin 39 is so long as to allow three different engaging possibilities for mobile keys 49 with pin 39 so as to connect shaft 21 with or disconnect it from either of motors 60 and 61.
Particularly in FIG. 6 it can be seen that each one of gears 72 meshes with a gear 74 splined to a shaft 75 supported by the outer wall of box element 70 and by one of its opposite inner walls so that it can turn. A bevel gear 76 is splined or fitted to shaft 75, and in turn gear 76 meshes with a circular face gear 77, which is fitted to outer shaft 67, thus getting movement from first control unit 60.
Each of gears 73 meshes with a gear 78 fitted to a shaft 79 supported by box element 70 almost in the same way as shaft 75, to which a bevel gear 80 is splined. This bevel gear meshes, in turn, with a circular face gear 81 that is fitted to inner shaft 66 and gets therefore motion from second control unit 61.
In this case the shape of pin 39 is slightly different from that in the first embodiment. In fact, as can be seen, particularly in FIG. 6, it has a second step-shaped part 83, against which a spring 82 engages itself. The other end of spring 82 engages itself with a steel sleeve 84 applied on pin 39. As for the rest, it is the same as what already described, particularly as far as the flared parts connecting reduced-diameter area 48 with the rest of pin 39 are concerned.
In particular, spring 82 is meant to perform, during one of the two possible engaging phases, the same function as spring 41 in the previous embodiment.
Also in this case the number of mobile keys is not limiting and it is possible to increase it according to the need.
Now are explained the various possibilities of mating splined shaft 21 to the various gears of the kinematic transmission mechanism in order to get the three working conditions of the same shaft, namely connection with either motor 60 or 61, or shaft not working.
With reference to FIG. 6, upper control unit 20 is not working, since smaller-diameter part 48 of pin 39 is engaged with all four mobile keys 49 and, therefore, both gear 72 and gear 73 are disengaged from shaft 21. On the contrary, lower control unit 20 is turning, being operated by motor 61.
This happens because, while two mobile keys 49 are engaged with smaller-diameter part 48, the other two are engaged with the greater-diameter part of pin 39. More precisely the engaged keys are those concerning gear 73, which will therefore make shaft 21 turn. Gear 73 is in mesh with gear 78, which gets movement through bevel gear 80 from gear 81 splined to inner shaft 66. Therefore shaft 21 in lower control unit 20 will be operated by motor 61.
The third possible working condition not shown turns out to be clear referring to control unit 20 in the upper part of FIG. 6 and supposing that pin 39 in this unit is lowered, i.e. radially moved towards the inside of drum 7. In this way a couple of mobile keys 49, i.e. those placed in the lower part of the picture, go on being engaged with smaller-diameter part 48 of pin 39, while the other two engage themselves on sleeve 84, the diameter of which is the same as that of pin 39, so gear 73 will be disengaged from shaft 21, while gear 72 is made integral with shaft 21 and makes it turn. Gear 72 is in mesh with gear 74 and gets movement through bevel gear 76 from circular gear 77 splined to outer shaft 67. In this case shaft 21 will get movement from other drive motor 60, which can be supposed to turn in the same sense as drive motor 61. What said means that two different control units 20, the first operated by drive motor 61 and the second by drive motor 60, will rotate simultaneously.
Also in this case an annular cam 54 accounts for the aforesaid movements of pins 39 in control units 20. This cam is situated around drum 7, but it is furnished with a series of recesses instead of only one recess as in the previous embodiment. However, by "a series of recesses" we do not mean a series of "identical" recesses as said in relation to the first embodiment, but fundamentally step-shaped recesses of such a kind as to get the three positions first above mentioned for various pins 39.
With particular reference to FIG. 5 cam 54 has, in this embodiment, a first recess 55 as in the first embodiment, followed, after a curvilinear step 55a, by a greater thickness or width zone of cam 54, after which there is again a curvilinear step 55b and then a zone with a thickness greater than the previous one.
Last zone 55c of cam 54 completing the cam circumference is even less thick, after a curvilinear step 55d. To realise clearly how this embodiment of the device works, it is enough to start with control unit 20 pointed at by arrow A in FIG. 5 and to go on following the revolution sense of the same, which is engaged with cam 54.
When aforesaid unit 20 gets into part 55, its pin 39 will be in the same condition as in control unit 20 in the lower part of FIG. 6, i.e. shaft 21 being connected to drive motor 61, as described hereinbefore.
When the same unit gets to the following zone after step 55a, its pin is in the middle condition corresponding to that of control unit 20 in the upper part of FIG. 6, where shaft 21 is not turning.
Finally, when the same unit gets to the following zone of cam 54 after step 55b, its pin 39 is taken into the position of maximum insertion in shaft 21, i.e. into the position not shown in FIG. 6, but described referring to it.
In this case shaft 21 is connected to drive motor 60.
Then, after curvilinear step 55d, control unit 20 gets to area 55c of cam 54, returning into the condition it was in, when moving along the area included between steps 55a and 55b.
It is clear that the embodiment shown is only an example of how to make two bars be fed simultaneously and independently. It is possible to choose the feed value required by adjusting the corresponding lathe stops scheduled in any known way.
Referring now to FIGS. 7 and 8, the third possible embodiment of the device of this invention is described. FIG. 7 shows a schematic rear view of the device, while FIG. 8 shows the device according to section VIII--VIII of FIG. 7. Also in this case the device consists of a fundamentally cylindrical revolving drum, marked with 7, inside which different control units 20 are not placed in a star-like manner as before, but they are arranged parallel to one another along a circumference, as shown schematically in FIG. 7. Each one of control units 20 is equipped with engaging and disengaging contrivances to be operated and stopped, as in the previous embodiments. In the present embodiment, these engaging and disengaging contrivances are ball clutches, which are operated through the combined action of the rotation of drum 7 and the engagement with a cam, that is marked with 54 also in this case.
Unlike in the other embodiments, cam 54 is a face cam and is placed opposite to one of the faces of drum 7, namely to that from which the cam followers of control units 20 project. In FIG. 8 the recesses and the projecting parts of cam 54 cannot be seen, but they are supposed to be in the same positions as in the previous figures.
Each control unit 20 is engaged with cam 54 through a wheel 46; this wheel turns on element 44, which slides inside a bushing 83 integral with drum 7 and engages itself with a thrust bearing 84. On the opposite face this thrust bearing engages itself with the end of a pin 39 sliding inside a shaft 21. Describing this construction variation, the same reference numbers have been used for those elements that are basically the same or that perform the same functions as in the previous embodiments.
Shaft 21 is supported by bearings 85 so that it can turn. These bearings are scheduled on an inner wall 86 of drum 7.
Pin 39 consists of a greater-diameter part 39a and a smaller-diameter part 48. In this way, through the sliding of pin 39 inside shaft 21, a ball 87 of a ball clutch provided with an operating spring 88 can get in through a hole in shaft 21 and not project out of this hole or, when it engages itself with greater-diameter part 39a of pin 39, it can project from this hole, as shown in particular in FIG. 8. In such position ball 87 engages shaft 21 with a gear 88, making shaft 21 turn.
Various gears 88 get movement from a drive motor 89, which is provided with a chain 90, winding around a gear 91 splined to a drive shaft 92.
Inside drum 7 a gear 93 is splined to drive shaft 92, and from gear 93 all gears 88 get movement through a continuous closed chain 94. Idle gears 95 are scheduled to keep chain 94 constantly under tension.
Control units 20 are operated and stopped basically in the same way as in the previous embodiments through pins 39 and ball clutches 87.
In fact, through its projecting parts cam 54 will account for making pin 39 go back. This pin (see FIG. 8) will move towards the left side, thus stopping control unit 20, which will be then operated again through spring 96, acting on a hollow part of pin 39 and taking it back towards the outside of drum 7, when wheel 46 meets a recess on cam 54.
The turning movement of shaft 21 is transmitted to the real drive shafts of the bar-pusher marked with 97 by means of a kinematic mechanism described in the following, with reference to a control unit 20.
A gear 98 is splined to shaft 21 and is in mesh with another gear 99, which is, in turn splined to a turning shaft 100 on drum 7 in the way shown, its longitudinal axis being perpendicular to that of shaft 21.
A gear 101 is splined to shaft 100 and is in mesh with an idle gear 102, which in turn is engaged with gear 103 splined to drive shaft 97. A gear 104 is splined to shaft 97 and operates its corresponding bar-pusher through a chain 105.
Trough a spline 106 provided on shaft 97 (FIG. 8), gear 104 can be moved and secured in different positions. As a consequence, drum 7 is provided with openings 57 on its front wall 9, which allow the corresponding movements of chains 105.
The way in which gears 104 are secured in the established positions on shafts 97 is known, therefore it is not shown.
As follows from what said up to now, the functioning principle of this embodiment of the device of this invention is basically the same as that of the previous embodiments, so that it is not described.
The descriptions of the different embodiments of the device highlight the advantages it offers and its great versatility, particularly as far as the second embodiment is concerned. Besides what said hereinbefore about the operation of this embodiment, it is to be noted that drive motors 60 and 61 can be equipped in any known way with speed variators or reversing gears, so that to have a chance to further increase the possibilities of changes in the working conditions of the device object of this invention.
It goes without saying that also variations of and/or changes in the device can be carried out, even the aforesaid variations and changes being covered by the rights coming from this invention.
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A control device for feeding metal bars to guide equipment for feeding an automatic multiple-spindle lathe. The device consists of a series of drive shafts, each of which accounts for the feeding of a bar. The shafts are equal in number to the lathe spindles and are placed in a drum that rotates synchronously with the lathe spindle holding drum. Each of these shafts can be coupled with a drive element when a certain length of bar is to be fed. The coupling takes place through engaging and disengaging parts mounted between the shaft and the drive element. Each shaft controls at least one gear for feeding a bar, through a chain or the like provided with a bar-pusher, when the shaft is made to turn. The gear can be moved to make the device usable with lathes having different spindle center distances.
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TECHNICAL FIELD
[0001] This invention relates to truck/trailer box constructions. More particularly, it relates to a sidewall construction for a truck/trailer box that is basically characterized by a plurality of horizontally elongated sidewall panels each composed of skins and webs that are too thin to be welded, and to a joint construction that permits the sidewall panels to be welded together where they join.
BACKGROUND OF THE INVENTION
[0002] There is a need for a way of constructing the sidewalls of truck/trailer boxes from materials that are very light weight but strong and rigid. There is also a need for such a truck/trailer box construction that permits sections of a sidewall to be welded together while still allowing for the use of very thin skins and webs that are themselves too thin to be welded.
[0003] There is also a need for a truck/trailer box sidewall construction that provides for the easy manufacture of both a top rail and a bottom rail for adding strength and rigidity to the tops and bottoms of the sidewalls.
[0004] The principal object of the present invention is to provide a truck/trailer sidewall construction that meets the above needs. Regarding the prior art, U.S. Pat. No. 5,052,741, granted Oct. 1, 1991, to Raynard Brown and Norval I. Lopshire discloses a truck box that is composed of a plurality of sidewall panels and an interlocking joint structure where edges of the panels meet. In the Background of the Invention portion of this patent, there is reference to the more common truck body sidewalls that are formed from plywood covered with an aluminum or plastic exterior surface. U.S. Pat. No. 5,791,726, granted Aug. 11, 1998, to Thomas N. Kaufman discloses a livestock trailer having sidewalls that are constructed from aluminum tubular members. The Background of the Invention section of this patent discloses and discusses several prior art trailers.
[0005] U.S. Pat. No. 4,785,929, granted Nov. 22, 1988, to Raymond K. Foster, and U.S. Pat. No. 5,096,356, granted Mar. 17, 1992, also to Raymond K. Foster disclose bottom constructions for truck/trailer boxes. The truck/trailer box sidewalls of the present invention are particularly adapted for use with the bottom constructions disclosed by these patents.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention includes providing a truck/trailer box sidewall construction that is characterized by a horizontally elongated bottom sidewall panel having a top edge, a bottom edge, inside and outside, vertical side skins, and a plurality of vertically spaced apart, horizontal webs interconnecting the side skins vertically between the top and bottom edges. The side skins and the webs together define a plurality of horizontally elongated inner spaces in said bottom sidewall panel. Each inner space is defined horizontally between the two side skins and vertically between the two webs. A horizontally elongated side rail may extend laterally outwardly from the inside skin of the sidewall at a location spaced above the bottom edge. The side rail has a bottom surface that forms a nook with a lower side surface of the inside side skin that extends downwardly from the bottom surface of the side rail. The top and bottom edges, the inside and outside vertical side skins, the horizontal webs and the side rail are all portions of a common extrusion.
[0007] According to another aspect of the invention, the truck/trailer sidewall further comprises a horizontally elongated top sidewall panel and a plurality of horizontally elongated intermediate sidewall panels. The intermediate sidewall panels are positioned vertically between the top sidewall panel and the bottom sidewall panel. The top sidewall panel has a top portion, a bottom edge, inside and outside vertical side skins, and a plurality of vertically spaced apart horizontal webs interconnecting the vertical side skins. The intermediate sidewall panels have top and bottom edges, inside and outside vertical side skins, and a plurality of vertically spaced apart horizontal webs interconnecting the vertical side skins. The bottom edge of the top sidewall panel is connected to the top edge of an adjacent intermediate wall panel that is below it. The top edge of the bottom wall panel is connected to the bottom edge of an adjacent intermediate sidewall panel that is above it. All other intermediate wall panels are connected to edges of the wall panel that is above it and the wall panel that is below it. When the top sidewall panel, the bottom sidewall panel and the intermediate sidewall panels are all connected together, the outside vertical side skins of all of said panels are substantially coplanar and the inside vertical side skins of all of said wall panels are substantially coplanar.
[0008] A further aspect of the invention is to provide a side rail that is integral with the inside side skin of the bottom sidewall panel. This sidewall projects laterally from the inside, vertical side skin.
[0009] The present invention also includes providing a truck/trailer box sidewall construction that comprises a horizontally elongated top sidewall panel having a top portion, a bottom edge, inside and outside, vertical side skins, and a plurality of vertically spaced apart, horizontal webs interconnecting the side skins vertically between the top portion and the bottom edge. The side skins and webs together define a plurality of horizontally elongated inner spaces in said top sidewall panel. Each said inner space is defined horizontally between the two side skins and vertically between two webs. The top portion of the top sidewall panel includes a top rail extending longitudinally of the top sidewall panel. The top edge rail is wider than the top sidewall panel and includes a vertical outside skin, a vertical inside skin, a top skin and a bottom skin, and at least one web extending between the side skins and dividing the top rail into inner spaces. The top rail and the bottom edge of the top sidewall panel, and the inside and outside vertical side skins, and the top and bottom skins of the top rail, and the horizontal webs in the top sidewall panel, and in the top rail, are all portions of a common extrusion.
[0010] The present invention further includes providing a truck/trailer box sidewall construction that is characterized by a lower, horizontally elongated, first sidewall panel and an upper, horizontally elongated second sidewall panel. The first sidewall panel has a top edge, vertical inside and outside side skins, and vertically spaced apart horizontal webs interconnecting the side skins vertically below the top edge and horizontally between the two side skins. The second sidewall panel has a lower edge, vertical inside and outside side skins, and horizontal webs interconnecting the side skins together vertically above the bottom edge and horizontally between the two side skins. The inside and outside skins of the first and second sidewall panels are too thin to be welded. One of the top and bottom edges includes a longitudinal groove and the other includes a longitudinal tongue that extends into the groove when the top and bottom edges are in contact. The first sidewall panel has corner regions that extend diagonally between the side skins and the top edge of the first wall section. The second sidewall panel has corner regions that extend diagonally between the side skins of the second sidewall section and the bottom edge of the second sidewall section. The corner regions together form horizontally extending weld recesses where the corner regions of the first sidewall panel adjoin the corner regions of the second sidewall panel when the top and bottom edges are in contact. The corner regions of the first and second sidewall panels are thick enough at the weld recesses to permit the placement of weld beads in the weld recesses. Weld beads are placed in the weld recesses and serve to weld the upper edge of the first sidewall panel to the lower edge of the second sidewall panel.
[0011] Other objects, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims and from the principles that are embodied in the specific structures that are illustrated and described.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0012] Like reference numerals are used to designate like parts throughout the several views of the drawing, and:
[0013] [0013]FIG. 1 is an end elevational view of a first extrusion that forms a top wall panel section of a trailer sidewall;
[0014] [0014]FIG. 2 is an end elevational view of a second extrusion that forms an intermediate wall panel section of the trailer sidewall;
[0015] [0015]FIG. 3 is an end elevational view of a third extrusion that forms a bottom wall panel section of a trailer sidewall;
[0016] [0016]FIG. 4 is an enlarged scale end elevational view showing the top edge portion of a lower wall panel spaced form a bottom edge portion of an adjacent upper wall panel;
[0017] [0017]FIG. 5 is a view like FIG. 4, but showing the two edge portions of the wall panels together and further showing welds connecting the wall panel sections together where they meet;
[0018] [0018]FIG. 6 is an enlarged scale fragmentary view of the lower portion of FIG. 3, showing an end portion of a transverse beam that extends cross the full width of the trailer and connects to the lower regions of the bottom sidewall panel sections of the trailer;
[0019] [0019]FIG. 7 is a view like FIG. 6, showing a reciprocating slat conveyor installed on the transverse beams, and further showing a relationship between an outside conveyor slat and the side rail that is a part of the extrusion that forms the bottom sidewall panel sections of the trailer sidewall;
[0020] [0020]FIG. 8 is an end elevational view of a modified top sidewall panel showing a top rail extrusion that is separate from the extrusion that forms the top sidewall panel; and
[0021] [0021]FIG. 9 is a view like FIG. 6, but showing a modified construction of the side rail, and showing the bottom sidewall panel section further including a bottom flange that is vertically spaced from the side rail, so as to define an elongated channel in which an end portion of a cross frame member, or a trailer floor section is received.
DETAILED DESCRIPTION OF THE INVENTION
[0022] [0022]FIG. 2 of the aforementioned U.S. Pat. No. 5,096,354 shows a reciprocating slat conveyor forming a floor in a material receiving compartment of a trailer box (TB) . The trailer box (TB)is shown to have a pair of sidewalls ( 14 , 16 ), a forward wall ( 18 ), a rear wall ( 20 ) and a floor or bottom ( 10 ). The rear wall ( 20 )is formed of a door or a pair of doors. The floor ( 10 )is shown to include transverse beams ( 36 ) on which the conveyor components rest. In FIGS. 2, 3 and 6 , the illustrated transverse beams are I-beams ( 36 ). The construction of the sidewalls is not disclosed and does not matter in that patent.
[0023] FIGS. 1 - 3 show components for making the sidewalls of a trailer box or similar container or compartment. Element 10 shown in FIG. 1 is a top panel section for a sidewall. Element 12 shown in FIG. 2 is an intermediate panel section. Element 14 shown in FIG. 3 is a bottom panel section. A typical sidewall is formed by one top panel section 10 , three intermediate panel sections 12 and one-bottom panel section 14 . The second sidewall can be formed by the same panel sections 10 , 12 , 14 . However, the top panel section 10 and the bottom panel section 14 would have to be turned end to end so that the top rail on top panel section 10 is projecting inwardly and the side rail 18 on bottom panel section 14 is directed inwardly. Because of the sidewall construction, it is only necessary to show one top panel section 10 , one intermediate panel section 12 and one bottom panel section 14 . When the two sidewalls are assembled, each is a mirror image of the other.
[0024] Top panel section 10 includes a top edge 20 that forms a part of the bottom or base of the top rail 16 . It further includes a bottom edge 22 , a pair of laterally spaced apart side skins 24 , 26 and a plurality of horizontal webs 28 . The top rail 16 includes an outside skin 30 , a top skin 32 , an inside skin 34 , and a bottom skin 36 and one or two webs 38 . All portions of the top panel section 10 are horizontally elongated, preferably for the full length of the trailer. The top edge 20 , a substantial portion of the bottom edge 22 , skins 32 , 36 and the webs 28 , 38 all extend horizontally. The side skins 24 , 26 , 30 , 34 extend vertically. As clearly shown by FIG. 1, outside skins 24 , 20 are different sections of a continuous single skin that extends from the bottom edge 22 up to the top skin 32 . Inside skin 34 is offset outwardly from inside skin 36 . Webs 28 and edge walls 20 , 22 divide the space that is laterally between the side skins 24 , 26 into horizontally elongated spaces 40 . Webs 38 define the space that is laterally between skins 30 , 32 into three spaces 42 . Spaces 40 , 42 are horizontally elongated spaces. As previously described, the top panel section 10 is a one-piece extrusion. It is preferably formed from a metal that is predominately aluminum.
[0025] The intermediate panel section 12 is also a one-piece extrusion. It has an upper edge wall 44 , a lower edge wall 46 , an outside skin 48 , an inside skin 50 and a plurality of webs 52 . Webs 52 divide the space that is laterally between skins 48 , 50 into smaller spaces 54 . Side skins 48 , 50 are parallel to each other in separate vertical planes. The webs 52 are parallel to each other in separate horizontal planes.
[0026] Bottom panel section 14 is also a continuous single piece extrusion. It is formed of outside and inside skins 56 , 58 that are in separate, parallel vertical planes. The space between the skins 56 , 58 is divided into smaller spaces by horizontal webs 60 . Webs 60 divide the larger space into smaller spaces or cells 62 . Bottom panel section 14 includes a top edge wall 66 and a bottom edge wall 70 . It also includes the aforementioned side rail 18 . In this embodiment, the side rail 18 has an inner wall 72 that includes the inside skin 58 plus some additional thickness. It also includes a top wall 74 , an inside wall 76 , and a bottom wall 78 . Walls 74 , 76 , 78 are substantially equal in thickness. Wall 72 has a thickness that is substantially the sum of the thickness of walls 76 and the skin 58 .
[0027] Near the bottom of the bottom panel section 14 , the outside skin 56 includes a recess 80 . Because the bottom panel section 14 is formed by extrusion, it is easy to provide the recess 80 and the side rail 18 to the rest of the extrusion. The recess 80 extends the full length of the bottom panel section 14 . A conspicuity tape is received within the recess 80 .
[0028] The sidewall panel sections 10 , 12 , 14 are connected together by weld beads 82 , one on each side of the sidewall. By way of example, the thickness dimension T for the top panel section 10 , below the top rail 16 , the entire intermediate panel section 12 , and the bottom panel section 14 , except at the side rail 18 and at the recess 80 may be substantially about 1 ½inches. The skins 24 , 26 , 30 , 48 , 50 , 56 , 58 and webs 28 , 52 , 60 may be substantially about 0.09 inches thick. The center-to-center dimension between adjacent webs 28 , 52 , 60 may be substantially about 1.763 inches. An important dimension is the thickness Z in the region of the welds 82 . In the example, this thickness is substantially about 0.188 inches. The weld recess width W is substantially about 0.250 inches. The weld recess depth D is substantially about 0.125 inches.
[0029] In preferred construction, the lower edge walls 22 , 46 are formed to include a longitudinally extending groove 84 . The top edges 44 , 68 are provided with a complementary longitudinally extending tongue 86 . As shown by FIG. 5, the tongue 86 makes a loose fit with the groove 84 . In the given example, the tongue width may be substantially about 0.1875 inches. The groove width may be substantially about 0.25 inches. The tongue length may be about 0.1825 inches. The groove depth may be substantially about 0.2475 inches. During assembly, two panel sections to be joined are brought together. The tongue 86 on one is inserted into the groove 84 in the other. Then, the side planes of the two panel sections are put into substantial coplanar alignment and the weld beads 82 are placed within the weld recess W, D. The tongue and groove components facilitate the welding process. If they were not present when the panels were welded together, the panels would expand and contract and become “wavy” down the length of the side. This would make it impossible to weld properly. It would be possible to “tack” weld every twelve inches on one side, but this would be impractical. The invention includes any type of tongue and groove system that holds the panels parallel to each other for welding purposes. For example, a two tongue and two groove system could be used.
[0030] At each joint, the diagonal corner regions 88 , 90 provide both structural reinforcement and width and depth for the weld beads W. A weld bead 82 that is substantially triangular in cross section, substantially about 0.250 inches wide, and substantially about 0.125 inches deep is made possible because of the thickness of the material in regions 88 , 90 . The corner regions 88 , 90 and the weld beads 82 together form outwardly widening flanges that, together with the wall sections 22 , 44 provide a reinforcing beam section at the location of each joint. This beam section extends the full length of the joint and its parts 22 , 44 , 82 , 88 , 90 in effect form I-beam like longitudinal stiffening and strengthening ribs at each joint location.
[0031] The panels 10 , 12 , 14 that make up a sidewall are laid flat on a jig. They are clamped and then tack welded about every four feet on the underneath side. They are no tack welds on the top. Then, all panels are welded the full length of the wall, simultaneously. The wall forming panel assembly is then flipped over to position its welded side facing downwardly. The wall structure is then clamped down and the new “up” side is welded the full length, simultaneously.
[0032] In the stated example, the width of top rail 16 may be substantially about 3.5 inches. The depth dimension, from the top of skin 32 to the bottom of skin 36 may measure substantially about 9.149 inches. The width dimension of skins 32 , 34 , 36 may be substantially about 0.1495 inches.
[0033] Referring to FIGS. 6 and 7, in the given example, the width and height outside dimensions of the side rail 18 may be substantially about 1.75 inches. Side rail 18 includes a bottom surface 92 that is substantially perpendicular to the side surface 94 of the bottom panel section 14 . The bottom surface 92 and the side surface 94 together form a substantially right angle “nook” in which end portions 96 of transverse frame beams 98 are received. In a manner known per se, the transverse beams 98 are parallel to each other and are spaced apart longitudinally of the trailer. In accordance with an aspect of the present invention, the end portions 96 of the beams 98 are welded to the side rail 18 and the lower portion of the bottom panel section 14 that depends downwardly from the side rail 18 . In the given example, the height dimensions H of the beams 98 is substantially about 5.25 inches. The flanged width a is substantially about 2 inches. The flange and web thicknesses b , c , is substantially about 0.25 inches. In the given example, the dimension d between the lower surface of the lower flange of beam 98 and the lower surface 70 of bottom panel section 14 is substantially about 0.25 inches. To a certain extent, the inside and outside skins of the first and second sidewall panels are too thin to be welded. They can be welded across the ribs but suffer stress cracking when welded along the ribs.
[0034] [0034]FIG. 7 shows a reciprocating slat conveyor mounted on the floor beams 98 . Longitudinal guide a support beams 100 are welded to the top flanges of the beams 98 . See also, for example, FIG. 11 of U.S. Pat. No. 4,785,929. Self-lubricated plastic bearings 102 are positioned on the beams 100 . Elongated conveyor slats 104 are positioned on the bearings 102 . The floor slats 104 are reciprocated lengthwise of the beams 100 . For example, they are all moved in unison from the front to the rear of the truck/trailer box. They are then stopped and are retracted, one third at a time. That is, slats 1 , 4 , 7 , etc. are retracted while the remaining slats remain stationary. Then, slats 2 , 5 , 8 , etc. are retracted while the others slats are stationary. Then, slats 3 , 6 , 9 , etc. are retracted while the other slats are stationary. Then, the cycle is repeated.
[0035] The conveyor slats 104 carry seal members 106 . The inside seal members 106 make a sliding sealing contact with an opposing side portion of an adjacent conveyor slat 104 . On the two sides of the conveyor, the seal strips 106 make sliding sealing contact with a surface 108 that is the inside vertical face of the side rail 18 . In the system shown by FIG. 7, the floor slat 104 that is adjacent the side rail 18 at the opposite side of the truck/trailer box includes two seal strips 106 . The inside seal strip 106 contacts a confronting surface of the next conveyor slat 104 that is to its inside. The outside seal strip 106 makes sealing contact with a side rail 18 that is like side rail 18 shown in FIG. 7, but projecting inwardly from the bottom sidewall panel 14 that is on the opposite side of the truck/trailer box.
[0036] As shown by FIG. 7, the skin portion 94 is thicker than the skin portions 56 , 58 . It is thick enough to allow the end portion of beams 98 to be welded to the skin portions 94 . The side rail 104 is also made thick enough so that it can welded to the top flanges of the transverse beams 98 .
[0037] [0037]FIG. 8 shows an alternate construction of the top panel 10 ′. Panel 10 ′ includes outer and inner skins 24 ′, 26 ′ and webs 28 ′. In this embodiment, the top rail 16 ′ is a separate extrusion from the remainder of the top panel 10 ′. It is formed to include a downwardly opening longitudinal channel 110 formed by and between side members 112 , 114 . The upper edge portion of the top panel 10 ′ fits in the channel 110 and is welded to the flanges 112 , 114 at 116 , 118 .
[0038] [0038]FIG. 9 shows a modified construction of the bottom panel 14 ′. It has vertically spaced apart upper and lower side rails 18 ′, 120 . The side rails 18 ′, 120 and wall portion 122 together form inwardly opening longitudinal channels 12 in which end portions of the floor beams 98 are received. The floor beams 98 may be welded to the side rails 18 ′, 120 at 126 , 128 .
[0039] Other floor constructions are within the scope of the present invention. For example, the floor structure may itself be formed by a plurality of joined together panels or extrusions, for example. Other floor constructions could be used as well.
[0040] The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein, but rather determined by the following claims, interpreted according to accepted doctrines of claim interpretation, including use of the doctrine of equivalents and reversal of parts.
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The sidewalls of a truck/trailer box are constructed from a plurality of panels ( 10, 12, 14 ) which are welded together where their vertical edges meet ( 82, 88, 90 ). The panels ( 10, 12, 14 ) are each extrusions and each includes thin side skins ( 24, 26 and 48, 50 and 56, 58 ) and thin webs ( 28, 52, 60 ). The top panel ( 10 ) may be formed to include an integral top rail ( 34 ). The bottom panel ( 14 ) may be formed to include one or two side rails ( 18, 18′ and 120 ). The regions that need to be welded are made thick enough to be welded. Other regions are too thin to be welded. The overall construction is lightweight and quite strong and facilitates construction of the truck/trailer box.
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FIELD OF THE INVENTION
This invention relates in general to drying green lumber, and relates in particular to an improved method and apparatus for kiln-drying mixed batches of lumber to a uniform dryness without overdrying some of the lumber.
BACKGROUND OF THE INVENTION
So-called "green" or freshly-cut lumber must be seasoned by drying the lumber to reduce the moisture content, before the lumber can be put to use. Although lumber can be dried by exposure to ambient air, that practice usually takes months to accomplish and the results seldom are uniform from one batch of lumber to the next. For these reasons, lumber is usually dried in a kiln where the temperature and relative humidity of the air are regulated in an effort to produce the desired moisture content within the lumber in the shortest possible time. Batches of lumber are stacked within the kiln so as to permit significant air circulation through the stack, and one or more such stacks usually are dried within the kiln at a time.
The charge of lumber in a kiln usually is a mix of dense- and coarse-grain lumber, with the relatively dense lumber containing more moisture and therefore requiring more energy (or greater drying time) to reach the desired moisture content. If the entire charge or batch of lumber is dried to meet the moisture-removal requirements of the dense lumber alone, the coarse-grain boards are ruined by overdrying. On the other hand, drying the entire batch of lumber only to reach the proper moisture content for the coarse-grain boards leaves the relatively dense boards with excess moisture, rendering them unsuitable for use without further drying. Although overdrying can be prevented by maintaining atmospheric conditions within the kiln to dry at a relatively slow rate which eventually produces the desired moisture content in the entire batch of lumber, that technique is unacceptably slow for effective commercial use.
Prior art kilns are known which attempt to deal in various ways with the problems of drying mixed-density batches of lumber. These efforts typically involve attempting to maintain a predetermined drying ability within the kiln by maintaining, for example, a constant wet-bulb temperature depression in the air within the kiln. U.S. patents to Reynolds (U.S. Pat. No. 3,386,183) and to Rosenau (U.S. Pat. No. 4,356,641) seek to control the wet-bulb temperature depression by controlling the heat input to the kiln. Gelineau (U.S. Pat. No. 4,599,808) attempts to maintain a predetermined constant rate of evaporation within a kiln by controlling the dry-bulb temperature drop in air flowing across the lumber, while maintaining a constant wetbulb temperature of the air upstream of the lumber. These efforts of the prior art have proven less than fully satisfactory, resulting either in overdrying the lumber or in drying unnecessarily slowly in an effort to avoid overdrying. To avoid overdrying in many instances, the kiln operator frequently must shut down the kiln long enough to sample the dryness of lumber at several locations within the kiln. These sampling steps, if properly done, can give the operator at least some idea of the additional energy (or drying time) required to reach the desired moisture content throughout the entire batch of lumber in the kiln. This sampling is at best a makeshift and inaccurate expedient, and further increases the overall drying time as the kiln must be shut down one or more times to allow sampling.
SUMMARY OF THE INVENTION
Stated in general terms, the amount of moisture in a batch of lumber being dried according to the present invention is equalized at a desired level by maintaining air within the kiln at a predetermined constant temperature and relative humidity, while varying the air flow across the lumber. The drop in temperature across the lumber is monitored, but is not controlled. When this temperature drop reaches a preset compliance point, no more energy is added to dry the lumber in the kiln. Air flow across the lumber thereafter continues for a further time, with the relatively wet more-dense lumber giving up moisture to the recirculating air and the relatively dry coarse-grained lumber taking on moisture from the air until the amount of moisture in the boards becomes substantially equalized across the entire batch of lumber.
Stated somewhat more particularly, the kiln is divided into two or more zones in which batches of lumber are placed, and through which the air flow is separately controlled. The inlet air dry bulb temperature is controlled in each zone, preferably by regulating the amount of steam flowing into that zone. The relative humidity within the kiln is adjusted by injecting steam and water, or by venting air from the kiln as necessary to maintain a constant wet bulb air temperature within the kiln. Air recirculates past the lumber in each zone by one or more fans separately associated with each zone, and the fans reverse direction at preset times so as to transpose the upstream and downstream sides of the lumber subjected to the recirculating air flow within the zones.
When the actual dry-bulb temperature drop across a particular zone reaches a preset temperature drop known as the compliance value, the air flow in that zone is reduced to a minimum value which prevents additional drying of the lumber in that zone. The other zones continue to dry until they also reach the preset compliance value. The fans for each zone are then reversed and compliance is again achieved with the opposite air flow. Upon reaching total compliance in all zones, the first drying cycle is complete and further heating and humidifying of air within the kiln is limited to the extend required to maintain reduced setpoint temperatures within the kiln and thereby prevent premature cooling; no further energy is added to the lumber, but the fans continue to circulate air across the lumber in each cell. This circulation continues for an equalization time period preselected by the kiln operator, with the direction of air flow being reversed at least once. The humidity within the kiln is relatively high when energy input to the lumber is stopped, preventing overdrying from occurring before the equalization period begins. During the equalization period, the dense boards continue to yield moisture to the recirculating air while the coarse boards absorb moisture from the air. The lumber thus dries to a given percentage of moisture, determined by the wet and dried bulb temperatures within the kiln and the kind of lumber being dried.
Accordingly, it is an object of the present invention to provide an improved kiln for drying green lumber.
It is another object of the present invention to provide a method and apparatus for drying lumber while avoiding overdrying the relatively coarse boards in a batch of lumber.
It is a further object of the present invention to provide a method and apparatus of drying lumber wherein the heat transfer to the lumber is controlled by varying the air flow across the lumber.
Other objects and advantages will become more apparent from the following description of a preferred embodiment.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic plan view of a kiln according to a preferred embodiment of the present invention.
FIG. 2 is a schematic view showing the environmental control apparatus used in the kiln of FIG. 1.
FIG. 3A, 3B, and 3C are flow diagrams illustrating a preferred mode of operating the kiln according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Turning first to FIG. 1, there is shown generally at 10 a kiln especially adapted for drying lumber according to the present invention. The kiln 10 has portals (not shown) at the entry end 11 for moving green or moist lumber into the kiln, and at the exit end 12 for moving seasoned or dry lumber out of the kiln. The kiln 10 is generally rectangular in plan view, with the longer axis being along the line extending between the entry end 11 and the exit end 12. The interior of the kiln is divided into three zones along the longitudinal axis, the zones appearing on FIG. 1 and identified herein as zone 1, zone 2, and zone 3. It should be understood that the choice of three zones is determined by the size of the kiln and is not considered a critical factor of the present invention.
Each zone within the kiln 10 is defined by removable baffles 15. These baffles may extend fully between the opposite side walls 16 and 17 of the kiln, although the baffles can fall somewhat short of the side walls without significantly detracting from the kiln operation as described herein. However, the baffles 15 should be easily retracted or repositioned within the kiln 10 to permit loading and unloading lumber in the kiln. In this regard, it should be understood that a fresh charge of green lumber typically is loaded at one time into all three zones of the kiln through the portal at the entry end 11; that lumber, once dry, is then removed from all zones through the portal at the exit end 12.
Each zone within the kiln 10 is equipped with selectively reversable fans for recirculating the air within the zones. These fans are denoted as 18a, 18b, and 18c for the three zones. Each group of fans 18a--18c preferably comprises a plurality of individually-controlled fans, so that the volume of air being recirculated through a particular zone can be reduced from the maximum available air flow by operating fewer than all available fans for that zone. In the specific example discussed herein, the group of fans for each zone has three individual fans for recirculating the air within that zone, but it should be understood that a greater or lesser number of fans may be used. Alternatively, variable-speed fans may be used to obtain the desired variations in the amount of air circulation through each individual zone.
Each zone within the kiln 10 has a separate dry bulb thermometer 20a, 20b, and 20c positioned on the right side of the kiln (as viewed in FIG. 1) for measuring the dry-bulb temperature of air recirculating through the respective zone. The zones likewise have separate dry bulb thermometers 21a . . . 21c positioned at the left sides of the zones. Moreover, separate wet bulb thermometers 22a . . . 22c and 23a . . . 23c are located at the right side and left side, respectively, of each zone within the kiln. The wet bulb thermometers 22a . . . 22c are associated with the right side of the kiln 10, and are located to sense the wet-bulb temperature of air moving downstream of the lumber. Likewise, the wet bulb thermometers 23a . . . 23c preferably are positioned at the left-side of the kiln 10, and sense downstream temperature when air flows leftwardly across the lumber in the kiln. Vents 28 and 29 are located in the roof of the kiln and are selectively openable as desired to reduce the relative humidity of air within the kiln by venting moisture-laden air from the kiln. As will become apparent, the vents 28 at the right side of the kiln 10 and the vents 29 on the left side are opened or closed in unison. The design of roof vents for lumber-drying kilns is known to those skilled in the art.
Apparatus for controlling the atmospheric environment within the kiln 10 is shown in FIG. 2. The air within the kiln is heated by two separate steam coils, the center coils 33 located at the center of the kiln and the top coils 34 located at the top thereof, in a manner known to those skilled in the art. Each set of coils is selectively connected to a boiler constituting the steam source 37 through the pneumatically-controlled flow valves 35 and 36, respectively. The flow valves 35 and 36 are operated in response to air pressure from the air source 38, by way of the respective transducers 39 and 40. Those transducers, in turn, receive electrical actuating signals on the lines 39a, 40a leading to the programmable controller 24. Condensate from the steam coils 33 and 34 is returned to the steam source by the returns 44.
Moisture is selectively added to the air within each zone of the kiln by means of the steam-water sprayers 41, 42, and 43 respectively associated with the three zones within the kiln. The sprayers 41-43 selectively receive conditioning water from the source 47 by way of the solenoid valves 48, 49, and 50, in response to signals received from the programmable controller 24. At the same time, the sprayers may be connected through the pressure reducer 52 and the flow valve 51 to the steam source 37, so that steam emanating from the sprayers is mixed with water in one or more of the sprayers, depending on which of the solenoid valves 48-50 is actuated. The flow valve 51 controlling steam to the sprayers 41-43 is actuated by the programmable controller.
The right roof vents 28 and left roof vents 29 are opened and closed by the air-powered actuators 55 and 56, controlled by the solenoid valve 57 in response to the programmable controller 24.
The programmable controller 24 used in the present embodiment is made by Allen-Bradley Company of Milwaukee, Wisconsin. The programmable controller 24 may connect to a microcomputer 25 to facilitate entry and change of the various operator-selectable parameters. The printer 26 connects to the computer 25 for printing reports of operator parameters and variables such as measured temperatures and operating times for each run of the kiln 10. The nature and operation of such programmable controllers are well known to those of ordinary skill in the art and need not be detailed herein apart from the following description of the process being controlled.
The operation of the present apparatus and method is now discussed with reference to FIG. 3. A charge of green lumber is moved into the kiln 10, and the baffles 15 are positioned to create the three distinct zones for recirculation of air within the kiln. The drying operation takes place in two sequential cycles, and the operator selects certain predetermined parameters for both cycles and enters those parameters into the programmable controller 24 before starting the drying operation. These operating parameters or setpoints include the dry and wet bulb temperatures for the first cycle, the minimum dry bulb temperature drop (dT) across the lumber constituting the "compliance value" selected to constitute the end of the first operating cycle, the minimum dry and wet bulb temperatures for the second cycle, and the equalization time constituting the duration of the second cycle. The nature and purpose of those setpoint values is discussed in greater detail below.
During the first cycle of operation, the air within the kiln is heated and humidified to predetermined setpoint values determined by factors including the kind of lumber being dried and the desired overall drying time commensurate with avoidance of overdrying. Another factor considered by the kiln operator in determining the setpoints is the desired final moisture content of the dried lumber. These factors to some extend are empirically determined, as is known to those skilled in the art.
The compliance point across a zone is reached when the dry bulb temperature drop of air flowing across the lumber in that zone reaches a value determined by the kiln operator to denote a predetermined moisture content of the lumber. The compliance point is separately reached for each zone within the kiln. As the compliance temperature across a zone is reached, the direction of air flow within that zone is then reversed until compliance is again reached across the zone. The air flow is reduced in each zone reaching compliance in both directions, so as to substantially eliminate further drying within that zone until the first cycle of drying is completed. When all zones reach compliance in both directions, the first cycle is complete and further energy input to the lumber is stopped. The second cycle now commences, providing a preset time for the humidity of the lumber within the kiln to equalize. The dT across the lumber is monitored while the dense and coarse boards seek equalization to the same moisture content during the second cycle. During this time the dense boards continue to yield moisture to the atmosphere while the coarse boards absorb moisture from the atmosphere, based on the fact that a board will dry to a given percent moisture for a given set of dry and wet bulb temperatures.
As a specific example of operating setpoints for the kiln according to the present invention, assume the kiln is charged with Southern Yellow Pine lumber. The dry bulb/wet bulb setpoints for the first cycle are 240° F. upstream of the lumber/200° F. downstream, and the kiln commences operation to achieve those setpoints in the atmosphere recirculating through the three zones. The dry bulb temperature drop across each zone is monitored to determine a point that indicates 35% relative humidity within each zone, a relatively high-humidity state corresponding to the compliance dT chosen for the particular lumber. When all zones are in compliance, the second cycle commences and dry bulb/wet bulb temperature setpoints of 150° F. upstream/140° F. downstream are utilized. Temperature and humidity within the kiln are monitored during the second cycle, and heat or moisture is added as needed to maintain the setpoints if the kiln cools too rapidly, e.g., due to rapid heat loss to air outside the kiln. However, it should be understood that no additional energy is supplied to dry the lumber during the second cycle. The equalization time is predetermined to allow all the lumber within the kiln to reach 15% moisture, the desired goal of dry Southern Yellow Pine.
It should be noted that the 15% moisture content goal could be achieved with lower dry bulb/wet bulb temperatures in the first cycle, for example, 150° F./140° F., but reaching a compliance point with such lower temperatures would require weeks rather than hours with the higher first-cycle temperatures noted previously. Those skilled in the art will realize that the dry bulb/wet bulb temperatures can be increased somewhat over the previous figures, provided the compliance point also is raised so as to avoid overdrying the relatively coarse lumber before the setpoint is reached and no further energy is introduced into the kiln to dry the lumber.
Once the kiln operator selects the various setpoints determined for the lumber being dried, the drying operation is started and the setpoints are loaded into the programmable controller as indicated at step 60 in FIG. 3A. As start-up commences, the programmable controller is instructed to close the vents 28 and 29 and start all the fans of each group of fans 18a-18c for maximum air flow in a first direction hereafter called the "forward" direction. The steam flow valves 35 and 36 also are opened at this time to commence heating the kiln based on the dry bulb setpoint temperature for the first cycle. The programmable controller preferably is programmed to gradually increase the kiln temperature with a start-up ramp, so as to limit the impact of a cold kiln on the boiler 37. This start-up ramp initially limits the amount of opening for the flow valves 35 and 36, thereby limiting the steam flow to the coils 33 and 35 during the predetermined time of the start-up ramp.
The fans 18a-18c run forwardly for a preset time during the first cycle, and then automatically reverse direction as indicated at step 61 in FIG. 3A. The amount of time between reversal of the fans is selectable by the kiln operator; three hours is typical for the first cycle of operation. By periodically reversing the direction of air recirculating through each zone, the effect of the relatively warm "upstream" air flowing onto the lumber is equalized across both sides of the lumber stacked in the kiln. This action continues with the programmable controller controlling the kiln temperature using the dry bulb temperature of air upstream of the lumber in each zone, to regulate steam flow within the kiln. The dry bulb thermometer 20a-20c are selected to measure upstream dry bulb temperature during forward fan operation, and the dry bulb thermometers 21a-21c are substituted by the programmable controller during reverse-flow operation. The relative humidity within the kiln is regulated by using the wet bulb temperature downstream of each zone, the roof vents being opened as necessary to vent overly-humid air from the kiln. Likewise, a steam/water mixture is introduced through one or more of the sprayers 41 . . . 43 if the monitored wet bulb temperatures indicate the moisture content of air within one or more zones of the kiln has fallen below the setpoint. However, no effort is made to control the temperature drop across a zone.
The programmable controller monitors the actual drop (dT) in dry bulb temperature across each zone. When the temperature drop across one of the zones reaches the preset value of dT, corresponding to the compliance value setpoint discussed above, the air flow in that particular zone is reduced to a minimum value as indicated at 62 in FIG. 3B. Reduction of air flow is accomplished by shutting down one or more of the multiple fans for recirculating the air within that zone. This reduction in air flow prevents additional drying of the lumber in the zone after the compliance value is reached. However, some minimum air flow across that zone is necessary to avoid stagnation of the air within that zone, thereby avoiding localized hot spots which may cause false temperature readings in an adjacent zone within the kiln.
After one of the zones first reaches compliance, the other zones continue to operate at normal fan speed and no further reversal of fan direction takes place until all zones reach the preset compliance value as indicated by the measured dry bulb temperature drops across those zones. This step is indicated at 64 in FIG. 3B. When all the zones have reached the compliance value, the fans for each zone are then reversed as indicated at 65, and all fans again operate to increase the air flow in each zone. Cycle 1 then continues with periodic reversal until compliance across each zone is again achieved with the opposite air flow. As with previous compliance, the air flow in each zone again reaching compliance is reduced as indicated at 65, FIG. 3C. It should be noted that if time in excess of a predetermined value is required for all zones to reach first compliance, the fans are reversed anyway as indicated at 66 in FIG. 3B and the first cycle continues toward the second compliance. Likewise, if a predetermined time passes without all zones being in compliance for the second time as indicated at 68, FIG. 3C, a condition of total compliance is nonetheless determined to exist as indicated at 67. At this time the first cycle of the drying process is complete and the timed second cycle commences.
The second cycle of kiln operation, as discussed above, takes place with no further energy added to the kiln except as required to maintain the minimum setpoints and prevent excessive cooling of the kiln. The lumber within the kiln cools down and the moisture equalizes across the dense and coarse lumber during the equalization time, as previously discussed. The equalization time is preselected by the kiln operator, and during that time the fans in all zones may reverse direction, for example, every hour during that equalization time. When the equalization time is complete as indicated at 70 in FIG. 3C, the second cycle is completed and the kiln is automatically shut down by the programmable controller. The controller may collect data concerning the measured temperatures and relative humidity during the overall drying cycle, and can prepare a printed report of that measured data at the end of the second cycle.
It should be understood that the foregoing relates only to a preferred embodiment of the invention, and that numerous modifications and changes therein may be made without departing from the spirit and scope of the invention as defined in the following claims.
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Lumber is dried in a kiln by controlling the temperature and humidity of air within the kiln during a first cycle, followed by a second cycle allowing humidity to equalize between the coarse and dense lumber in the kiln without adding further energy. Air recirculates across the lumber in the kilm, and the drop in dry bulb air temperature across the lumber indicates the dryness of the lumber. The air temperature within the kiln is maintained at a predetermined setpoint, but no attempt is made to control the temperature drop across the lumber. Upon reaching a predetermined temperature drop across the lumber, corresponding to a relatively high amount of moisture in the kiln, no further energy is supplied to the kiln and air recirculation continues for a time to allow equalization of moisture in all lumber within the kiln. The process yields a desired uniform amount of moisture in the lumber while avoiding overdrying of the relatively coarse lumber in the kiln.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 61/122,434, filed Dec. 15, 2008, incorporated herein by reference, is hereby claimed.
U.S. Pat. No. 7,281,589 is incorporated herein by reference.
U.S. patent application Ser. No. 11/778,956, filed Jul. 17, 2007, is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND
In top drive rigs, the use of a top drive unit, or top drive power unit is employed to rotate drill pipe, or well string in a well bore. Top drive rigs can include spaced guide rails and a drive frame movable along the guide rails and guiding the top drive power unit. The traveling block supports the drive frame through a hook and swivel, and the driving block is used to lower or raise the drive frame along the guide rails. For rotating the drill or well string, the top drive power unit includes a motor connected by gear means with a rotatable member both of which are supported by the drive frame.
During drilling operations, when it is desired to “trip” the drill pipe or well string into or out of the well bore, the drive frame can be lowered or raised. Additionally, during servicing operations, the drill string can be moved longitudinally into or out of the well bore.
The stem of the swivel communicates with the upper end of the rotatable member of the power unit in a manner well known to those skilled in the art for supplying fluid, such as a drilling fluid or mud, through the top drive unit and into the drill or work string. The swivel allows drilling fluid to pass through and be supplied to the drill or well string connected to the lower end of the rotatable member of the top drive power unit as the drill string is rotated and/or moved up and down.
Top drive rigs also can include elevators are secured to and suspended from the frame, the elevators being employed when it is desired to lower joints of drill string into the well bore, or remove such joints from the well bore.
At various times top drive operations, beyond drilling fluid, require various substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as the top drive unit is rotating and/or moving the drill or well string up and/or down, but bypassing the top drive's power unit so that the substances do not damage/impair the unit. Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movement by the top drive unit of the drill or well string.
A need exists for a device facilitating insertion of various substances downhole through the drill or well string, bypassing the top drive unit, while at the same time allowing the top drive unit to rotate and/or move the drill or well string.
One example includes cementing a string of well bore casing. In some casing operations it is considered good practice to rotate the string of casing when it is being cemented in the wellbore. Such rotation is believed to facilitate better cement distribution and spread inside the annular space between the casing's exterior and interior of the well bore. In such operations the top drive unit can be used to both support and continuously rotate/intermittently reciprocate the string of casing while cement is pumped down the string's interior. During this time it is desirable to by-pass the top drive unit to avoid possible damage to any of its portions or components.
The following U.S. Patents are incorporated herein by reference: U.S. Pat. Nos. 4,722,389 and 7,007,753.
While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. One embodiment relates to an assembly having a top drive arrangement for rotating and longitudinally moving a drill or well string. In one embodiment is provided a swivel apparatus, the swivel generally comprising a mandrel and a sleeve with a packing configuration, the swivel being especially useful for top drive rigs.
In one embodiment the sleeve can be rotatably and sealably connected to the mandrel. The swivel can be incorporated into a drill or well string, enabling string sections both above and below the sleeve to be rotated in relation to the sleeve. Additionally, the swivel provides a flow path between the exterior of the sleeve and interior of the mandrel while the drill string is being rotated and/or being moved in a longitudinal direction (up or down). The interior of the mandrel can be fluidly connected to the longitudinal bore of the casing or drill string thereby providing a flow path from the exterior of the sleeve to the interior of the casing/drill string.
In one embodiment is provided a method and apparatus for servicing a well wherein a swivel is connected to a top drive unit for conveying pumpable substances from an external supply through the swivel for discharge into the well string and bypassing the top drive unit.
In another embodiment is provided a method of conducting servicing operations in a well bore, such as cementing, comprising the steps of moving a top drive unit rotationally and/or longitudinally to provide longitudinal movement and/or rotation in the well bore of a well string suspended from the top drive unit, rotating the drill or well string and supplying a pumpable substance to the well bore in which the drill or well string is manipulated by introducing the pumpable substance at a point below the top drive power unit and into the well string.
In other embodiments are provided a swivel placed below the top drive unit can be used to perform jobs such as spotting pills, squeeze work, open formation integrity work, kill jobs, fishing tool operations with high pressure pumps, sub-sea stack testing, rotation of casing during side tracking, and gravel pack or frack jobs. In still other embodiments a top drive swivel can be used in a method of pumping loss circulation material (LCM) into a well to plug/seal areas of downhole fluid loss to the formation and in high speed milling jobs using cutting tools to address down hole obstructions. In other embodiments the top drive swivel can be used with free point indicators and shot string or cord to free stuck pipe where pumpable substances are pumped downhole at the same time the downhole string/pipe/free point indicator is being rotated and/or reciprocated. In still other embodiments the top drive swivel can be used for setting hook wall packers and washing sand.
In still other embodiments the top drive swivel can be used for pumping pumpable substances downhole when repairs/servicing is being done to the top drive unit and rotation of the downhole drill string is being accomplished by the rotary table. Such use for rotation and pumping can prevent sticking/seizing of the drill string downhole. In this application safety valves, such as TIW valves, can be placed above and below the top drive swivel to enable routing of fluid flow and to ensure well control.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIGS. 1A and 1B are a schematic views showing a top drive rig with one embodiment of a top drive swivel incorporated in the drill string;
FIG. 2 is a perspective view of one embodiment of a top drive swivel;
FIG. 3 is a sectional view of a mandrel which can be incorporated in the swivel of FIG. 2 ;
FIG. 4 is a perspective view of a sleeve, clamp, and torque arm which can be incorporated into the swivel of FIG. 2 ;
FIG. 5 is an exploded view of the sleeve, clamp, and torque arm of FIG. 4 ;
FIG. 6 is a cutaway perspective view of the swivel of FIG. 2 ;
FIGS. 7A and 7B include a sectional view of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
FIG. 8 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 2 ;
FIG. 9 is a perspective view of a spacer;
FIG. 10 is a top view of the spacer of FIG. 9 ;
FIG. 11A is a sectional side view of the spacer of FIG. 9 ;
FIG. 11B is an enlarged sectional side view of the spacer of FIG. 9 ;
FIG. 12 is a perspective view of a female backup ring;
FIG. 13 is a top view of the female backup ring of FIG. 12 ;
FIG. 14A is a sectional side view of the female backup ring of FIG. 12 ;
FIG. 14B is an enlarged sectional side view of the female backup ring of FIG. 12 ;
FIG. 15 is a perspective view of a seal ring;
FIG. 16 is a top view of the seal ring of FIG. 15 ;
FIG. 17A is a sectional side view of the seal ring of FIG. 15 ;
FIG. 17B is an enlarged sectional side view of the seal ring of FIG. 15 ;
FIG. 18 is a perspective view of a rope seal;
FIG. 19 is a top view of the rope seal of FIG. 18 ;
FIG. 20A is a sectional side view of the rope seal of FIG. 18 ;
FIG. 20B is an enlarged sectional side view of the rope seal of FIG. 18 ;
FIG. 21 is a perspective view of a seal ring;
FIG. 22 is a top view of the seal ring of FIG. 21 ;
FIG. 23A is a sectional side view of the seal ring of FIG. 21 ;
FIG. 23B is an enlarged sectional side view of the seal ring of FIG. 21 ;
FIG. 24 is a perspective view of a seal ring;
FIG. 25 is a top view of the seal ring of FIG. 24 ;
FIG. 26A is a sectional side view of the seal ring of FIG. 24 ;
FIG. 26B is an enlarged sectional side view of the seal ring of FIG. 24 ;
FIG. 27 is a perspective view of a male backup ring;
FIG. 28 is a top view of the male backup ring of FIG. 27 ;
FIG. 29A is a sectional side view of the male backup ring of FIG. 27 ;
FIG. 29B is an enlarged sectional side view of the male backup ring of FIG. 27 ;
FIGS. 30A and 30B include a sectional view of another embodiment of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
FIG. 31 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 30A ;
FIG. 32 is a perspective view of a spacer;
FIG. 33 is a top view of the spacer of FIG. 32 ;
FIG. 34A is a sectional side view of the spacer of FIG. 32 ;
FIG. 34B is an enlarged sectional side view of the spacer of FIG. 32 ;
FIG. 35 is a perspective view of a female backup ring;
FIG. 36 is a top view of the female backup ring of FIG. 35 ;
FIG. 37A is a sectional side view of the female backup ring of FIG. 35 ;
FIG. 37B is an enlarged sectional side view of the female backup ring of FIG. 35 ;
FIG. 38 is a perspective view of a seal ring;
FIG. 39 is a top view of the seal ring of FIG. 38 ;
FIG. 40A is a sectional side view of the seal ring of FIG. 38 ;
FIG. 40B is an enlarged sectional side view of the seal ring of FIG. 38 ;
FIG. 41 is a perspective view of a rope seal;
FIG. 42 is a top view of the rope seal of FIG. 41 ;
FIG. 43A is a sectional side view of the rope seal of FIG. 41 ;
FIG. 43B is an enlarged sectional side view of the rope seal of FIG. 41 ;
FIG. 44 is a perspective view of a seal ring;
FIG. 45 is a top view of the seal ring of FIG. 44 ;
FIG. 46A is a sectional side view of the seal ring of FIG. 44 ;
FIG. 46B is an enlarged sectional side view of the seal ring of FIG. 44 ;
FIG. 47 is a perspective view of a seal ring;
FIG. 48 is a top view of the seal ring of FIG. 47 ;
FIG. 49A is a sectional side view of the seal ring of FIG. 47 ;
FIG. 49B is an enlarged sectional side view of the seal ring of FIG. 47 ;
FIG. 50 is a perspective view of a male backup ring;
FIG. 51 is a top view of the male backup ring of FIG. 50 ;
FIG. 52A is a sectional side view of the male backup ring of FIG. 50 ;
FIG. 52B is an enlarged sectional side view of the male backup ring of FIG. 50 ;
FIG. 53 shows an alternative combination swivel and ball dropper;
FIG. 54 shows one embodiment of the ball dropper for the combination swivel and ball dropper of FIG. 53 .
DETAILED DESCRIPTION
Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
FIGS. 1A and 1B are schematic views showing a top drive rig 1 with one embodiment of a top drive swivel 30 incorporated into drill string 20 . FIG. 1A shows a rig 1 having a top drive unit 10 . Rig 1 comprises supports 16 , 17 ; crown block 2 ; traveling block 4 ; and hook 5 . Draw works 11 uses cable 12 to move up and down traveling block 4 , top drive unit 10 , and drill string 20 . Traveling block 4 supports top drive unit 10 . Top drive unit 10 supports drill string 20 .
During drilling operations, top drive unit 10 can be used to rotate drill string 20 which enters wellbore 14 . Top drive unit 10 can ride along guide rails 15 as unit 10 is moved up and down. Guide rails 15 prevent top drive unit 10 itself from rotating as top drive unit 10 rotates drill string 20 . During drilling operations drilling fluid can be supplied downhole through drilling fluid line 8 and gooseneck 6 .
As shown in FIG. 1B , during operations swivel 30 can be connected to rig 1 through clamp 600 and torque arm 630 . Torque are 630 can be pivotally connected to swivel 30 and can resist rotational movement of swivel sleeve 150 relative to rig 1 . Torque arm 630 can be slidably connected to rig 1 to allow a certain amount of longitudinal movement of swivel 30 with drill string 20 .
At various times top drive operations, beyond drilling fluid, require substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as top drive unit 10 is rotating and/or moving drill or well string 20 up and/or down and bypassing top drive unit 10 so that the substances do not damage/impair top drive unit 10 . Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movements of drill or well string 20 being moved/rotated by top drive unit 10 . This can be accomplished by using top drive swivel 30 .
Top drive swivel 30 can be installed between top drive unit 10 and drill string 20 . One or more joints of drill pipe 18 can be placed between top drive unit 10 and swivel 30 . Additionally, a valve can be placed between top drive swivel 30 and top drive unit 10 . Pumpable substances can be pumped through hose 31 , swivel 30 , and into the interior of drill string 20 thereby bypassing top drive unit 10 . Top drive swivel 30 is preferably sized to be connected to drill string 20 such as 4½ inch (11.43 centimeter) IF API drill pipe or the size of the drill pipe to which swivel 30 is connected to. However, cross-over subs can also be used between top drive swivel 30 and connections to drill string 20 . Two sizes for swivel 30 will be addressed in this application—a 4½ inch (11.43 centimeter) version and a 6⅝ inch (16.83 centimeter) version.
FIG. 2 is a perspective view of one embodiment of a swivel 30 . Swivel 30 can be comprised of mandrel 40 and sleeve 150 . Sleeve 150 can be rotatably and sealably connected to mandrel 40 . Accordingly, when mandrel 40 is rotated, sleeve 150 can remain stationary to an observer insofar as rotation is concerned. As will be discussed later inlet 200 of sleeve 150 is and remains fluidly connected to a the central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 .
FIG. 3 is a sectional view of mandrel 40 which can be incorporated in swivel 30 . Mandrel 40 can be comprised of upper end 50 and lower end 60 . Central longitudinal passage 90 can extend from upper end 50 through lower end 60 . Lower end 60 can include a pin connection 80 or any other conventional connection. Upper end 50 can include box connection 70 or any other conventional connection. Mandrel 40 can in effect become a part of drill string 20 . Sleeve 150 can fit over mandrel 40 and become rotatably and sealably connected to mandrel 40 . Mandrel 40 can include shoulder 100 to support sleeve 150 . Mandrel 40 can include one or more radial inlet ports 140 fluidly connecting central longitudinal passage 90 to recessed area 130 . Recessed area 130 preferably forms a circumferential recess along the perimeter of mandrel 40 and between packing support areas 131 , 132 . In such manner recessed area 130 will remain fluidly connected with radial passage 190 and inlet 200 of sleeve 150 (see FIGS. 6 and 7A ).
Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 52 and 5/16 inches (132.87 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. NC50 is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Such tool joint designation is equivalent to and interchangeable with 4½ inch (11.43 centimeter) IF (Internally Flush), 5 inch (12.7 centimeter) XH (Extra Hole) and 5½ inch (13.97 centimeter) DSL (Double Stream Line) connections. Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 6⅝ inch (16.83 centimeters) outer diameter and a 2¾ inch (6.99 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 1,477,000 pounds (6,570 kilo newtons) tensile load at the minimum yield stress; (b) 62,000 foot-pounds (84 kilo newton meters) torsional load at the minimum torsional yield stress; and (c) 37,200 foot-pounds (50.44 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
In another embodiment, Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 67 and 13/16 inches (172.24 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. 6⅝ inch (16.83 centimeters) FH is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 8½ inch (21.59 centimeter) outer diameter and a 4¼ inch (10.8 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 2,094,661 pounds (9,318 kilo newtons) tensile load at the minimum yield stress; (b) 109,255 foot-pounds (148.1 kilo newton meters) torsion load at the minimum torsional yield stress; and (c) 65,012 foot-pounds (88.14 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
To reduce friction between mandrel 40 and packing units 305 , 405 and increase the life expectancy of packing units 305 , 405 , packing support areas 131 , 132 can be coated and/or sprayed welded with a materials of various compositions, such as hard chrome, nickel/chrome or nickel/aluminum (95 percent nickel and 5 percent aluminum) A material which can be used for coating by spray welding is the chrome alloy TAFA 95MX Ultrahard Wire (Armacor M) manufactured by TAFA Technologies, Inc., 146 Pembroke Road, Concord N.H. TAFA 95 MX is an alloy of the following composition: Chromium 30 percent; Boron 6 percent; Manganese 3 percent; Silicon 3 percent; and Iron balance. The TAFA 95 MX can be combined with a chrome steel. Another material which can be used for coating by spray welding is TAFA BONDARC WIRE—75B manufactured by TAFA Technologies, Inc. TAFA BONDARC WIRE—75B is an alloy containing the following elements: Nickel 94 percent; Aluminum 4.6 percent; Titanium 0.6 percent; Iron 0.4 percent; Manganese 0.3 percent; Cobalt 0.2 percent; Molybdenum 0.1 percent; Copper 0.1 percent; and Chromium 0.1 percent. Another material which can be used for coating by spray welding is the nickel chrome alloy TAFALOY NICKEL-CHROME-MOLY WIRE-71T manufactured by TAFA Technologies, Inc. TAFALOY NICKEL-CHROME-MOLY WIRE-71T is an alloy containing the following elements: Nickel 61.2 percent; Chromium 22 percent; Iron 3 percent; Molybdenum 9 percent; Tantalum 3 percent; and Cobalt 1 percent. Various combinations of the above alloys can also be used for the coating/spray welding. Packing support areas 131 , 132 can also be coated by a plating method, such as electroplating. The surface of support areas 131 , 132 can be ground/polished/finished to a desired finish to reduce friction and wear between support areas 131 , 132 and packing units 305 , 415 .
FIG. 4 is a perspective view of a sleeve 150 , clamp 600 , and torque arm 630 which can be incorporated into swivel 30 . FIG. 5 is an exploded view of the components shown in FIG. 4 . FIG. 6 is a cutaway perspective view of swivel 30 . FIG. 7A is a sectional view of swivel 30 taken along the line 7 A- 7 A of FIG. 6 .
FIG. 6 is an overall perspective view (and partial sectional view) of top drive swivel 30 . Sleeve 150 is shown rotatably connected to mandrel 40 . Bearings 145 , 146 allow sleeve 150 to rotate in relation to mandrel 40 . Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Retaining nut 800 retains sleeve 150 on mandrel 40 . Inlet 200 of sleeve 150 is fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 ; passing through radial passage 190 ; passing through recessed area 130 ; passing through one of the plurality of radial inlet ports 40 ; passing through central longitudinal passage 90 ; and exiting mandrel 40 through central longitudinal passage 90 at lower end 60 and pin connection 80 .
Sleeve 150 can include central longitudinal passage 180 extending from upper end 160 through lower end 170 . Sleeve 150 can also include radial passage 190 and inlet 200 . Inlet 200 can be attached by welding or any other conventional type method of fastening such as a threaded connection. If welded the connection is preferably heat treated to remove residual stresses created by the welding procedure. Lubrication port 210 (not shown) can be included to provide lubrication for interior bearings. Packing ports 220 , 230 can also be included to provide the option of injecting packing material into the packing units 305 , 405 . A protective cover 240 can be placed around packing port 230 to protect packing injector 235 . Optionally, a second protective cover can be placed around packing port 220 . Sleeve 150 can include a groove 691 for insertion of a key 700 . FIG. 7A illustrates how central longitudinal passage 90 is fluidly connected to inlet 200 through radial passage 190 .
Sleeve 150 slides over mandrel 40 . Bearings 145 , 146 rotatably connect sleeve 150 to mandrel 40 . Bearings 145 , 146 are preferably thrust bearings although many conventionally available bearing will adequately function, including conical and ball bearings. Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Inlet 200 of sleeve 150 is and remains fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 (arrow 201 ); passing through radial passage 190 (arrow 202 ); passing through recessed area 130 (arrow 202 ); passing through one of the plurality of radial inlet ports 140 (arrow 202 ), passing through central longitudinal passage 90 (arrow 203 ); and exiting mandrel 40 via lower end 60 at pin connection 80 (arrows 204 , 205 ).
Sleeve 150 is preferably fabricated from 4140 heat treated round mechanical tubing having the following properties: (120,000 psi (827,400 kilo pascal) minimum tensile strength, 100,000 psi (689,500 kilo pascal) minimum yield strength, and 285/311 Brinell Hardness Range). In one embodiment the external diameter of sleeve 150 is preferably about 11 inches (27.94 centimeters). Sleeve 150 preferably resists high internal pressures of fluid passing through inlet 200 . Preferably top drive swivel 30 with sleeve 150 will withstand a hydrostatic pressure test of 12,500 psi (86,200 kilo pascal). At this pressure the stress induced in sleeve 150 is preferably only about 24.8 percent of its material's yield strength. At a preferable working pressure of 7,500 psi (51,700 kilo pascal), there is preferably a 6.7:1 structural safety factor for sleeve 150 .
To minimize flow restrictions through top drive swivel 30 , large open areas 140 are preferred. Preferably each area of interest throughout top drive swivel 30 is larger than the inlet service port area 200 . Inlet 200 is preferably 3 inches having a flow area of 4.19 square inches (27.03 square centimeters). In one embodiment the flow area of the annular space between sleeve 150 and mandrel 40 is preferably 20.81 square inches (134.22 square centimeters). The flow area through the plurality of radial inlet ports 140 is preferably 7.36 square inches (47.47 square centimeters). The flow area through central longitudinal bore 90 is preferably 5.94 square inches 38.31 square centimeters).
Retainer nut 800 can be used to maintain sleeve 150 on mandrel 40 . Retainer nut 800 can threadably engage mandrel 40 at threaded area 801 . Set screw 890 can be used to lock in place retainer nut 800 and prevent nut 800 from loosening during operation. A set screw 890 (not shown for clarity) can threadably engages retainer nut 800 through bore 900 (not shown for clarity) and sets in one of a plurality of receiving portions 910 formed in mandrel 40 . Retaining nut 800 can also include grease injection fitting 880 for lubricating bearing 145 . A wiper ring 271 (not shown for clarity) can be set in area 270 protects against dirt and other items from entering between the sleeve 150 and mandrel 40 . A grease ring 291 (not shown for clarity) can be set in area 290 for holding lubricant for bearing 145 .
Bearing 146 can be lubricated through a grease injection fitting 211 and lubrication port 210 (not shown for clarity).
FIGS. 4 and 5 best show clamp 600 which can be incorporated into top drive swivel 30 . FIG. 5 is an exploded view of clamp 600 . Clamp 600 can comprises first portion 610 , second portion 620 , and third portion 625 . First, second, and third portions 610 , 620 , 625 can be removably attached by plurality of fasteners 670 , 680 . Key 700 can be inserted in keyway 690 of clamp 600 . A corresponding keyway 691 is included in sleeve 150 of top drive swivel 30 . Keyways 690 , 691 and key 700 prevent clamp 600 from rotating relative to sleeve 150 . A second key 720 can be installed in keyways 710 , 711 . Third, fourth, and additional keys/keyways can be used as desired.
Shackles can be attached to clamp 600 to facilitate handing top drive swivel 30 when clamp 600 is attached. Torque arm 630 can be pivotally attached to clamp 600 and allow attachment of clamp 600 (and sleeve 150 ) to a stationary part of top drive rig 1 preventing sleeve 150 from rotating while drill string 20 is being rotated by top drive 10 (and top drive swivel 30 is installed in drill string 20 ). Torque arm 630 can be provided with holes for attaching restraining shackles. Restrained torque arm 630 prevents sleeve 150 from rotating while mandrel 40 is being spun. Otherwise, frictional forces between packing units 305 , 405 and packing support areas 131 , 135 of rotating mandrel 40 would tend to also rotate sleeve 150 . Clamp 600 is preferably fabricated from 4140 heat treated steel being machined to fit around sleeve 150 .
FIG. 8 shows a blown up schematic view of packing unit 305 . FIG. 7B shows a sectional view through packing area 305 . Packing unit 305 can comprise female packing end 330 ; packing ring 340 , packing lubrication ring 350 , packing ring 360 , packing ring 370 , and packing end 380 . Packing unit 305 sealing connects mandrel 40 and sleeve 150 . Packing unit 305 can be encased by packing retainer nut 310 , spacer 320 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 305 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . Packing unit 405 (shown in FIG. 7A ) can be constructed substantially similar to packing unit 305 . The materials for packing unit 305 and packing unit 405 can be similar.
Spacer 320 can comprise, first end 322 , second end 324 , internal surface 326 , and external surface 328 . Spacer 320 can be sized based on the amount of squeezed to be applied to packing unit 305 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
Packing end 330 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 330 can comprise tip 332 with concave portion 331 . Concave portion 331 can have an angle of about 130 degrees at its center. Tip 332 can include side 333 , recessed area 334 , peripheral groove 337 and inner diameter 335 . Recessed area 334 and inner diameter 335 can be configured to minimize contact of female packing ring or end 330 with mandrel 40 . Instead, contact will be made between packing ring 340 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 330 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 340 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi (20,700 kilo pascals or 27,600 kilo pascals)). It is also believed that packing rings 370 and/or 360 perform the majority of sealing against lower pressure fluids. Female packing ring 330 can include a plurality of radial ports 336 fluidly connecting peripheral groove 337 with interior groove 338 to allow packing injected to evenly distribute around ring and into the actual sealing rings.
Packing ring 340 can comprise tip 342 , base 344 , internal surface 346 , and external surface 348 . Tip 342 can have an angle of about 120 degrees to have an non-interference fit with tip 332 of female packing end 330 which is at about 130 degrees Base 344 can have an angle of about 120 degrees. Packing ring 340 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 342 of packing ring 340 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 334 of the female packing ring or end 330 which would cause side 333 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 344 being at about 120 degrees is believed to assist in causing packing ring 340 to bear against mandrel 40 , and not side 333 of female packing ring 330 .
Packing lubrication ring 350 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 350 is shown after be shaped by packing rings 340 and 360 .
Packing ring 360 can comprise tip 362 , base 364 , internal surface 366 , and external surface 368 . Tip 362 can have an angle of about 90 degrees. Base 364 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 360 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
Packing rings 360 , 370 can have substantially the same geometric construction. Packing ring 370 can comprise tip 372 , base 374 , internal surface 376 , and external surface 378 . Tip 372 can have an angle of about 90 degrees. Base 374 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 370 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
In an alternative embodiment both packing rings 360 and 370 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
In another alternative embodiment packing ring 370 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 360 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
Male packing end or ring 380 can comprise tip 382 , base 384 , internal surface 386 , and external surface 388 . Tip 382 can have an angle of about 90 degrees. Packing end 380 is preferably an aluminum bronze male packing ring.
Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
Using the above packing configuration it has been surprisingly found that packing life in a displacement job at high pressure can be extended from about 45 minutes to about 10 hours, at rotation speeds of about 30, about 40, about 50, and about 60 revolutions per minute.
In installing packing units 305 , 405 , it has been found that the packing units should first be compressed in a longitudinal direction between sleeve 150 and a dummy cylinder (the dummy cylinder serving as mandrel 40 ) before sleeve 150 is installed on mandrel 40 . This is because a certain amount of longitudinal compression of packing units 305 , 405 will occur when fluid pressure is first exerted on these packing units. This longitudinal compression will be taken up by the respective packing retainer nuts 310 . However, using a dummy cylinder allows the individual packing retainer nuts 310 to cause pre-fluid pressure longitudinal compression on packing units 305 , 405 , but still allow the seals to maintain an internal diameter consistent with the external diameter of mandrel 40 . Such a procedure can avoid the requirement of resetting the individual packing retainer nuts 310 after fluid pressure is applied to the packing units causing longitudinal compression.
Female packing ring or end 330 can include a packing injection option. Injection fitting 225 can be used to inject additional packing material such as teflon into packing unit 305 . Head 226 for injection fitting 225 can be removed and packing material can then be inserted into fitting 225 . Head 226 can then be screwed back into injection fitting 225 which would push packing material through fitting 225 and into packing port 220 . The material would then be pushed into packing ring or end 330 . Packing ring or end 330 can comprise a plurality of radial ports 336 , outer peripheral groove 337 , and inner peripheral groove 338 . The material would proceed through outer groove 337 , through the plurality of radial ports 336 , and through inner peripheral groove 338 causing a sealing effect. The interaction between injection fitting 235 and packing unit 405 can be substantially similar to the interaction between injection fitting 225 and packing unit 305 . A conventionally available material which can be used for packing injection fittings 225 , 235 is DESCO™ 625 Pak part number 6242-12 in the form of a 1 inch by ⅜ inch (2.54 centimeter by 0.95 centimeter) stick and distributed by Chemola Division of South Coast Products, Inc., Houston, Tex.
Injection fittings 225 , 235 have a dual purpose: (a) provide an operator a visual indication whether there has been any leakage past either packing units 305 , 405 and (b) allow the operator to easily inject additional packing material and stop seal leakage without removing top drive swivel 30 from drill string 20 .
FIGS. 30A through 50 show an alternative packing arrangement for packing units 305 , 405 . In this alternative arrangement spacer 420 can include a plurality of radial ports for injecting packing filler material.
FIG. 31 shows a blown up schematic view of packing unit 405 . FIG. 30B shows a sectional view through packing unit 405 . Packing unit 405 can comprise female packing end 430 ; packing ring 440 , packing lubrication ring 450 , packing ring 460 , packing ring 470 , and packing end 480 . Packing unit 405 sealing connects mandrel 40 and sleeve 150 . Packing unit 405 can be encased by packing retainer nut 310 , spacer 420 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 405 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . An upper packing unit can be constructed substantially similar to packing unit 405 . The materials for packing unit 405 and upper packing unit can be similar.
Spacer 420 can comprise, first end 421 , second end 422 , internal surface 423 , and external surface 424 . Spacer 420 can be sized based on the amount of squeezed to be applied to packing unit 405 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
Packing end 430 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 430 can comprise tip 432 with concave portion 431 . Concave portion 431 can have an angle of about 130 degrees at its center. Tip 442 can include side 433 , recessed area 44 , peripheral groove 47 and inner diameter 445 . Recessed area 434 and inner diameter 435 can be configured to minimize contact of female packing ring or end 430 with mandrel 40 . Instead, contact will be made between packing ring 440 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 430 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 440 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi) (20,700 kilo pascals or 27,600 kilo pascals). It is also believed that packing rings 470 and/or 460 perform the majority of sealing against lower pressure fluids.
Packing ring 440 can comprise tip 442 , base 444 , internal surface 446 , and external surface 448 . Tip 442 can have an angle of about 120 degrees to have an non-interference fit with tip 432 of female packing end 430 which is at about 130 degrees Base 444 can have an angle of about 120 degrees. Packing ring 440 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 442 of packing ring 440 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 434 of the female packing ring or end 430 which would cause side 433 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 444 being at about 120 degrees is believed to assist in causing packing ring 440 to bear against mandrel 40 , and not side 433 of female packing ring 430 .
Packing lubrication ring 450 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 450 is shown after being shaped by packing rings 440 and 460 .
Packing ring 460 can comprise tip 462 , base 464 , internal surface 466 , and external surface 468 . Tip 462 can have an angle of about 90 degrees. Base 464 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 460 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
Packing rings 460 , 470 can have substantially the same geometric construction. Packing ring 470 can comprise tip 472 , base 474 , internal surface 476 , and external surface 478 . Tip 472 can have an angle of about 90 degrees. Base 474 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 470 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
In an alternative embodiment both packing rings 460 and 470 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
In another alternative embodiment packing ring 470 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 460 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
Male packing end or ring 480 can comprise tip 482 , base 484 , internal surface 486 , and external surface 488 . Tip 482 can have an angle of about 90 degrees. Packing end 480 is preferably an aluminum bronze male packing ring.
Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
FIG. 53 shows an alternative combination swivel and ball dropper.
FIG. 54 shows one embodiment of the ball dropper for the combination swivel and ball dropper of FIG. 53 .
The following is a list of reference numerals:
LIST FOR REFERENCE NUMERALS
(Part No.)
(Description)
Reference Numeral
Description
1
rig
2
crown block
3
cable means
4
travelling block
5
hook
6
gooseneck
7
swivel
8
drilling fluid line
10
top drive unit
11
draw works
12
cable
13
rotary table
14
well bore
15
guide rail
16
support
17
support
18
drill pipe
19
drill string
20
drill string or work string
30
swivel
31
hose
40
swivel mandrel
50
upper end
60
lower end
70
box connection
80
pin connection
90
central longitudinal passage
100
shoulder
110
interior surface
120
external surface (mandrel)
130
recessed area
131
packing support area
132
packing support area
140
radial inlet ports (a plurality)
145
bearing
146
bearing
150
swivel sleeve
155
protruding section
156
shoulder
157
shoulder
158
packing support area
159
packing support area
160
upper end
170
lower end
180
central longitudinal passage
190
radial passage
200
inlet
201
arrow
202
arrow
203
arrow
204
arrow
205
arrow
210
lubrication port
211
grease injection fitting
220
packing port
225
injection fitting
226
head
230
packing port
235
injection fitting
240
cover
250
upper shoulder
260
lower shoulder
270
area for wiper ring
271
wiper ring (preferably Parker part number
959-65)
280
area for wiper ring
281
wiper ring (preferably Parker part number
959-65)
290
area for grease ring
291
grease ring (preferably Parker part number
2501000 Standard Polypak)
300
area for grease ring
301
grease ring (preferably Parker part number
2501000 Standard Polypak)
305
packing unit
310
packing retainer nut
314
bore for set screw
315
set screw for packing retainer nut
316
threaded area
317
set screw for receiving area
320
spacer
322
first end
324
second end
326
internal surface
328
external surface
330
female packing end and packing injection
ring
331
concave portion
332
tip
333
side
334
recessed area
335
inner diameter
336
radial port
337
peripheral groove
338
interior groove
340
packing ring
342
tip
344
base
346
internal surface
348
external surface
350
packing ring
360
packing ring
362
tip
364
base
366
internal surface
368
external surface
370
packing ring
372
tip
374
base
376
internal surface
378
external surface
380
packing end
382
tip
384
base
386
internal surface
388
external surface
405
packing unit
410
packing retainer nut
414
bore for set screw
415
set screw for packing retainer nut
416
threaded area
417
set screw for receiving area
420
spacer and packing injection ring
421
first end
422
second end
423
internal surface
424
external surface
437
radial port
438
peripheral groove
439
interior groove
430
female packing end
431
concave portion
432
tip
433
side
434
recessed area
435
inner diameter
436
external diameter
440
packing ring
442
tip
444
base
446
internal surface
448
external surface
450
packing ring
460
packing ring
462
tip
464
base
466
internal surface
468
external surface
470
packing ring
472
tip
474
base
476
internal surface
478
external surface
480
packing end
482
tip
484
base
486
internal surface
488
external surface
600
clamp
605
groove
610
first portion
620
second portion
625
third portion
630
torque arm
650
shackle
660
shackle
670
plurality of fasteners
680
plurality of fasteners
690
keyway
691
keyway
700
key
710
keyway
711
keyway
720
key
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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For use with a top drive power unit supported for connection with a well string in a well bore to selectively impart longitudinal and/or rotational movement to the well string, a feeder for supplying a pumpable substance such as cement and the like from an external supply source to the interior of the well string in the well bore without first discharging it through the top drive power unit including a mandrel extending through a sleeve which is sealably and rotatably supported thereon for relative rotation between the sleeve and mandrel. The mandrel and sleeve have flow passages for communicating the pumpable substance from an external source to discharge through the sleeve and mandrel and into the interior of the well string below the top drive power unit. The unit can include a packing injection system and novel seal configuration.
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FIELD OF THE INVENTION
The invention concerns Vertical Cavity Surface Emitting Lasers.
BACKGROUND OF THE INVENTION
Stacks of alternating high and low refractive index layers serve as mirrors in Vertical Cavity Surface Emitting Lasers, hereinafter referred to as VCSELs. The task is to find suitable materials for the high and low index layers which maximize a ratio of the high index refractive order to the low index refractive order, and which could be deposited in a manner compatible with the semiconductor device processing.
A VCSEL is attractive as a device in which the lasing cavity is perpendicular to the top surface of a laser chip, which is small and which may be produced by planar technology. This can lead to a promising future in high density laser arrays, high data transmission in optical communication systems, ultra high parallel processing in optical communication systems, as well as supplying a route for data transmission between electronic chips. Furthermore, the circular-like nature of their beams allows one to efficiently couple the laser light into circular optical fibers.
In the VCSEL the light output is in the film growth direction which is usually parallel to the direction of the injection current. Due to this feature, the mirror through which the emission takes place and the electrical contact physically occupy the same side of the laser structure, i.e. either the top or the bottom of the device. The mirror is located approximately in the center of the surface while the electrode is located peripherally of the mirror. An example of a surface emitting laser with a coplanar mirror/electrode arrangement in which a gold layer with a thickness of a few tenths of a micrometer acts as the mirror through which laser-emission takes place, may be found in articles by H. Soda et al., entitled "GaInAsP/InP Surface Emitting Injection Lasers," Japanese Journal of Applied Physics, Vol. 18, No. 12, 1979, pp. 2329-2230; and by H. Soda et al. entitled "GaInAsP/InP Surface Emitting Injection Lasers with Short Cavity Length," IEEE Journal of Quantum Electronics, Vol. QE-16, No. 6, Jun. 1983, pp. 1035.1041. However, S. Kinoshita pointed out that such mirrors lead to low quantum efficiency primarily due to absorption of lasing emission by the gold mirror and suggested the use of a stack of pairs of dielectric layers as the top mirror, one layer of each pair having a higher index of refraction than the other layer of the pair. See an article by Susumu Kinoshita et al. entitled "GaAlAs/GaAs Surface Emitting Laser with High Reflective TiO 2 /SiO 2 Multilayer Bragg Reflector," Japanese Journal of Applied Physics, vol. 26, No. 3, March 1987, pp. 410-415; L. M. Zinkiewicz et al., "High Power Vertical-Cavity Surface-Emitting AlGaAs/GaAs Diode Lasers," Appl. Phys. Letters, Vol. 54, No. 20, 15 May 1989, pp. 1959-1961; and Kenichi Iga, "Recent Advances of Surface Emitting Semiconductor Lasers," Optoelectronics-Devices and Technologies, Vol. 3, No. 2, December 1988, pp. 131-142.
TiO 2 and ZrO 2 quarter-wave ##EQU1## dielectric layers have been typically paired with SiO 2 quarter-wave layers. The number of pairs is selected to obtain a maximum performance reflectivity. However, the mirror structure of alternating TiO 2 (or ZrO 2 ) and SiO 2 quarter-wave layers have not yielded expected performance, in terms of reflectivity. Theoretically, the optical performance of a stacked mirror structure should approach 100 percent. Unfortunately, presently obtainable performance falls within a broad range of from 90 to 99 percent. The problem resides, primarily, with the high index layer materials. This shortfall is, most likely, due to the difficulty in obtaining sufficiently high quality TiO 2 (or ZrO 2 ) layers on a reproducible basis. Electron-beam deposition of coatings, such as TiO 2 (or ZrO 2 ), requires addition of oxygen in the deposition process to get the proper stoiciometry for a desired refractive index. Addition of oxygen is needed to avoid formation of unwanted, oxygen-deficient phases, such as Ti, TiO, Ti 2 O 3 , Ti 3 O 5 , which occur due to an oxygen shortage. This requirement makes it difficult to reproducibly form the TiO 2 layer.
Several single crystal semiconductors with high index of refraction, such as Al x Ga 1-x As or GaInP, which possess the desired properties when epitaxially deposited may be used in place of TiO 2 or ZrO 2 layers; however, the epitaxial growth of these materials requires temperatures of ˜600°-800° C. along with sophisticated, expensive growth apparatus. These materials are poorly suited for deposition in a device post-processing wherein temperatures above 300°-350° C. are to be avoided. Therefore, there is still a need for high stability, high performance mirrors for use in VCSELs with high quality coatings which are easily reproducible at conditions compatible with the device processing and which could be also produced in a simplified manner utilizing planar technology.
SUMMARY OF THE INVENTION
This invention embodies a VCSEL with a top mirror comprising at least one pair of quarterwave layers, each pair consisting of a low index of refraction layer and a high index of refraction layer, the high index of refraction layer being a semiconductor chosen from GaP and ZnS and the low index of refraction layer being chosen from borosilicate glass (BSG), CaF 2 , MgF 2 and NaF. Especially useful in vertical cavity surface emitting lasers are mirrors formed by a stack of a plurality of pairs of GaP/BSG or ZnS/CdF 2 . Such mirrors are produced by e-beam deposition in the absence of oxygen and have a high reflectivity characteristics required for an efficient operation of the laser. The GaP/BSG or ZnS/CaF 2 mirror structures represent a considerable improvement over previous designs for VCSELs in terms of ultimate reflectivity, low loss, and post growth processing compatibility.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view of a structure of a VCSE Laser;
FIG. 2 is a chart representing a Reflectivity versus Wavelength curve measured for a mirror with 6 pairs of ZnS/CaF 2 .
FIG. 3 is a chart representing a Reflectivity versus Wavelength curve measured for a mirror with 3 pairs of GaP/borosilicate glass; and
FIG. 4 is a chart representing the measured optical data for a 40 nm thick GaP film on borosilicate glass in terms of transmission and reflection.
DETAILED DESCRIPTION
The applicants have discovered that such a semiconductor materials as GaP and ZnS represent an excellent choice for the high index layers in mirrors for use in VCSELs especially if combined with such low index dielectric layers as CaF 2 , MgF 2 , NaF and borosilicate glass (BSG). The index of refraction of GaP is 3.45, of ZnS is 2.35, and BSC, CaF 2 , MgF 2 , NaF the index of refraction is 1.46, 1.42, 1.389, and 1.317, respectively. GaP and ZnS are compound semiconductor which can be deposited by electron-beam (E-beam) evaporation in the form of amorphous layers, at relatively low substrate temperatures and without the need for oxygen supply during the deposition. E-beam evaporation, a relatively inexpensive technique, produces no significant damage to the semiconductor surface and permits in situ monitoring of the layer thickness. E-beam evaporation is well-known in the art and, thus, does not need any further elaboration. For an example of a suitable apparatus for a two layer deposition by e-beam technique see the article by Susumu Kinoshita, et al., supra, or U.S. Pat. No. 3,984,581 issued to Herman R. Dobler et al. on Oct. 5, 1976.
E-beam deposition of GaP and ZnS in absence of oxygen leads to deposits which are in an amorphous rather than crystalline state if the substrate temperature is maintained during deposition at a temperature within a range of from room temperature to 250° C. These temperatures are compatible with present commonly used device processes, such as oxide deposition or metallizations. Although the deposited layers are not single crystal, absorption losses are low for wavelengths within a range of from 0.5 to 1.6 μm, preferably from 0.5 to 1.1 μm and most preferably from 0.85 to 0.88 μm (emission wavelength of bulk GaAs). Good quality GaP and ZnS layers are obtained independently of the substrate material making such mirror structures as GaP/BSG or ZnS/CaF 2 readily reproducible. In contrast to the use of TiO 2 or unmodified ZrO 2 , in combination with SiO 2 layers, control of film stoichiometry using GaP or ZnS as a high index coating is not a problem, and leads to an excellent reproducibility.
FIG. 1 is a schematic representation of a VCSEL according to this invention, denominated generally as 10. For reasons of clarity elements of the VCSEL are not drawn to scale. VCSEL 10 comprises a substrate 11; a quarter-wave stack of a plurality of pairs of semiconductor layers forming a bottom mirror, 12, one layer of each pair having a refractive index different from the refractive index of another layer of the pair; a first confining layer, 13; an active layer, 14; a second confining layer, 15; a highly-doped contact layer, 16; a metal ring which acts as a non-alloyed ohmic top electrode, 17, of the device; a second quarter-wave stack of a plurality of pairs of layers forming a top mirror, 18, one layer of each pair having a refractive index different from the refractive index of another layer of the pair; and a bottom electrode, 19, in contact with the bottom surface of substrate 11. While not shown, additional confining and buffer layers may be included into the laser structure. The number of pairs of layers is arbitrarily shown as being 3; however, this number may be anyone within a range of from 2 to 20.
Construction of VCSEL 10, in accordance with the invention, may be described as being generally as follows:
Substrate 11 is an n + -type III-V or II-VI semiconductor, such as GaAs, GaInAs, InP, GaInP, GaInPAs, AlAs, AlGaAs, AlGaInAs, AlInP, AlInPAs, AlGaInPAs and other related group III-V or II-VI compound semiconductors. Typically, the thickness of the substrate ranges from 100 to 500 μm and the doping concentration of the substrate ranges from 1×10 17 to 1×10 19 cm -3 . In some applications, such as opto-electronic integrated circuitry, substrate 11 may be first grown on a master substrate of silicon, which is in common to a number of devices grown on the master substrate.
Quarter-wave stack 12 is composed of a plurality of pairs (or periods) of layers of n + -type semiconductor, such as GaAs. GaInAs, InP, GaInP, GaInAsP, AlAs, AlGaAs, AlInP, AlGaInP, AlGaInAsP, the semiconductor layers forming a bottom multilayer distributed Bragg reflector (DBR) mirror with a number of pairs typically ranging from 10 to 40. One semiconductor layer in each pair has a higher index of refraction than the other semiconductor layer of the pair. The thickness of each semiconductor layer in the pair equals ##EQU2## wherein λ is the optical wavelength of the laser device and n is the refractive index of the layer. For example, for a device with an active region lasing at λ≃0.87 μm, such as a GaAs-based laser, a quarter-wave stack of pairs of such semiconductors as GaAs and AlAs with refractive indices of 3.64 and 2.97, respectively, will consist of 60 nm thick GaAs layer and 73 nm thick AlAs layer while a stack of Al 0 .05 Ga 0 .95 As and AlAs will consist of pairs of layers 62 nm and 73 nm thick each, respectively.
First confining layer 13 and second confining layer 15 are provided to confine active region 14 and to adjust the length (L) of an optical cavity (that is, the thickness of the active region). The optical cavity length should be 2L=N·λ, wherein N is an integer and λ is an operating optical wavelength of the laser. Typically, the thickness of each confining layer ranges from 0 to 3 μm. To obtain constructive interference, the thickness of the confining layers should be a multiple of ##EQU3## In the preferred embodiment the confining regions are of Al x Ga 1-x As, with x ranging from 0.1 to 0.4.
Active region 14 is a region in which electrons (-) and holes (+) recombine providing, under proper stimulation, a lasing emission. In the preferred embodiment, the active region is a lightly doped (1×10 16 -5×10 17 cm -3 ) layer of GaAs with a thickness within a range from 0.1 to 1 μm. The single layer may be a homogeneous semiconductor or a single or multiple quantum well (QW) structure, composed of a narrower gap semiconductor confined by a wider gap semiconductor. Alternatively, the single layer forming the active region may be replaced by a superlattice structure which is a multiquantum well structure with very thin barriers.
Highly doped contact layer 16 is provided in thickness of from 0.01 to 0.1 μm to facilitate establishing a non-alloyed ohmic contact between confining layer 15 and ring electrode 17. Typically, the doping concentration in the contact layer ranges from 1×10 19 to 1×10 20 cm -3 .
Electrode 17 is a non-alloyed ohmic contact. Electrode 17 is of a metal selected from such metal composites as AuBe and AuZn deposited in a thickness of from 5 to 400 nm thick in the form of an annulus with from 1.0 to 50 μm outer diameter and from 0.5-25 μm inner diameter. Such contacts are deposited by evaporation at temperatures ranging from 20° C. to 500° C., preferably from 20° C. to 250° C. Higher temperatures could result in undesirable alloying of the metal into the semiconductor. Additionally, a thin layer of such metal as Pt may be positioned between contact layer 16 and the metal composite.
Top mirror 18 is a multilayer Bragg reflector including from 2 to 20 pairs of high index and low index layers stacked one upon another in a columnar fashion. In one preferred embodiment the high index layers are GaP and the low index layers are borosilicate glass (BSG) such as Vycor®. In another preferred embodiment, the high index layers are Zns layers and the low index layers are CaF 2 layers.
Metal electrode 19 from 1 to 10 μm thick is formed on the bottom surface of substrate 11 to provide for current flow perpendicularly through the active region to cause lasing emission. The laser may be mounted with electrode 19 in contact with a heat-sink plate, e.g. of copper or some or some other heat-conductive material which does not contaminate the materials of the laser.
Semiconductor layers 12 through 16 can be grown upon substrate 11 by such known methods as metal organic vapor phase epitaxy (MOVPE), also known as metal organic chemical vapor deposition (MOCVD), or by Molecular Beam Epitaxy (MBE) or by hydride vapor phase epitaxy (VPE). In the preferred embodiment, the VCSEL structures are grown by the MBE technology in a Varian Gen II MBE system on heavily doped GaAs substrates 11. After layers 12 through 16 are grown, the partially formed structure is transferred to a separate high vacuum chamber where a metal layer is deposited by electron beam evaporation on exposed portions of contact layer 16 as a non-alloyed ohmic contact in a thickness sufficient to provide desired electrical conductivity. Electrode 17 may be deposited through a photolithographically formed mask or through a shadow mask blocking off areas on which deposition of the metal electrode is to be excluded, such as the centrally located area of the contact layer. Following the top electrode deposition step, the top mirror stack is deposited in absence of oxygen through a shadow mask by electron beam evaporation either in the same or in another chamber. Bottom electrode layer 19, e.g., of In, may then be formed on the bottom surface of substrate 11. Finally, the bottom side of the laser may be mounted via the In electrode or by means of a conductive adhesive, such as epoxy, on a copper slab which serves as a heat sink in common to other devices.
The flow of electrons from top electrode 17 may be restrictively directed to the active layer through a small contrally located window (not shown) defined in confining layer 15. This central area preferably corresponds substantially to the central opening in the annular electrode. It maybe produced conveniently by ion-implanting the peripheral area of confining layer 15 with ions which do not affect the conductivity type of the material in which they are implanted. Proton ions, such as H + ,O + or He + are implanted typically in concentrations ranging from 1×10 18 to 5×10 19 per cm 3 . They are implanted into the peripheral area of confining layer 15 prior to the deposition of contact layer 16, thus defining a window for the centrally restricted flow of electrons to active layer 14.
In the exemplary preferred embodiment, the VCSEL is an Al x Ga 1-x As laser structure, with x ranging from 0 to 1.0, comprising in an ascending sequence 1 to 2 μm thick In electrode 19, about 500 μm thick (001)-oriented heavily doped (2×10 18 cm -3 ) n + -GaAs substrate 11, bottom mirror 12 consisting of a quarter-wave stack of 30 pairs of n + -type (5×10 17 -5×10 18 cm -3 ) semiconductor layers forming multilayer distributed Bragg reflector (DBR) mirror, each pair of the stack consisting of a 73 nm thick layer of n + -AlAs and 62 nm thick layer of Al 0 .05 Ga 0 .95 As. The reflectivity spectrum of this DBR structure, as measured with a Perkin-Elmer Lambda 9 UV/VIS/NIR Spectrophotometer, showed a broad high reflectivity band centered at ˜0.87 μm with a reflectivity>99 percent. The bottom mirror is followed by first confinement layer 13 of n + -Al 0 .20 Ga 0 .80 As (5×10 17 cm -3 ) about 3 μm thick, lightly doped (5×10 16 cm -3 ) active layer 14 of p - -GaAs about 0.6 μm thick, and second confinement layer 15 of p + -Al 0 .30 Ga 0 .70 As (5×10 16 cm -3 ) about 0.5 μm thick. A heavily doped (5×10 19 cm -3 ) contact layer 16 of p + -Al 0 .10 Ga 0 .90 As, about 0.06 μm thick, is deposited on confining layer 15 for ohmic contact purpose. Electrode layer 17 of AuBe about 200 nm thick is formed, through a suitable mask, on top of contact layer 16 under conditions leading to a non-alloyed ohmic contact. Electrode layer 17 is in the form of an annulus with from 1.0 to 50.0 μm, preferably 5 to 25 μm, outer diameter and about from 0.5 to 20 μm, preferably 2 to 20 μm, inner diameter.
A plurality of alternating layers of GaP and BSG or ZnS and CaF 2 , forming top mirror 18 are then deposited by e-beam evaporation. These layers are deposited through a mask so as to form a cylindrical column of alternating layers. The deposition begins with a BSG (or CaF 2 ) layer followed by the deposition of GaP (or ZnS, respectively) layer and repetition of the deposit sequence until a desired number, e.g., 20, of BSG-GaP (or CaF 2 -ZnS) pairs are deposited. The stack is then preferably capped off with another BSG (or CaF 2 ) layer.
The source material for deposition of GaP layers was polycrystalline GaP and for deposition of BSG layers was fused BSG. Similarly, the source material for deposition of ZnS layers was crystalline ZnS and for deposition of CaF 2 layers was crystalline CaF 2 . After bombardment of the source materials was initiated, an about 150 nm thick BSG (about 153 nm thick CaF 2 ) layer was permitted to be deposited on an adjacent central region of contact layer 16 and in partially overlapping relation on exposed portions of contact 17 while the deposition of GaP was avoided by means of a shutter. Thereafter about 64 nm thick GaP (about 93 nm thick ZnS) layer was deposited while the deposition of the BSG layer was interrupted. This procedure sequence was repeated until a desired number of pairs (periods) of BSG and GaP (or CaF 2 and ZnS, respectively) layers was deposited. During the deposition, the vacuum was kept within a range of from 1×10 -4 to 1×10 -7 Torr. Outer diameter of the stack was larger than the inner diameter of electrode 17 so as to overlap the electrode by from 0.2 to 5 μm. During the deposition the substrates were held at temperatures of 125° C.-250° C. These temperatures are compatible with device processes, such as oxide deposition or metallization, commonly used as a post semiconductor growth processing. These temperatures are also conducive to the formation of amorphous films of GaP and ZnS in absence of an oxygen atmosphere. E-beam evaporation of alternating GaP and BSG layers or ZnS and CaF 2 layers in accordance with this invention produces desired index of refraction without introduction of oxygen into the evaporation chamber. Thus, there was no need to introduce oxygen into the chamber, and none was introduced.
FIG. 2 shows a reflectivity versus wavelength curve measured for a six pair ZnS/CaF 2 quarter-wave mirror on Si. A reflectivity of >97% is obtained at a wavelength range of from 0.80 to 0.90 μm.
FIG. 3 shows a reflectivity versus wavelength curve measured for a 3 pair GaP/BSG quarter-wave mirror on Si. A reflectivity of >97% is obtained at a wavelength of about 0.87 μm. Additionally, a measured optical data in terms of transmission and reflection is shown in FIG. 4 for a 400Å GaP film deposited at a substrate temperature of 250° C. Over the wavelength range of 0.7-1.1 μm no measurable absorption takes place in the GaP film.
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This invention embodies a Vertical Cavity Surface Emitting Laser with a top mirror comprising at least one pair of quarterwave layers, each pair consisting of a low index of refraction layer and a high index of refraction layer, the high index of refraction layer being a semiconductor chosen from GaP and ZnS and the low index of refraction layer being chosen from borosilicate glass (BSG) CaF 2 ,MgF 2 and NaF. Especially useful in vertical cavity surface emitting lasers are mirrors formed by a stack of a plurality of pairs of GaP/BSG or ZnS/CdF 2 . Such mirrors have a high reflectivity characteristics required for an efficient operation of the laser. The GaP/BSG or ZnS/CaF 2 mirror structure represents a considerable improvement over previous designs for VCSELs in terms of ultimate reflectivity, low loss, and post growth processing compatibility.
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BACKGROUND OF THE INVENTION
[0001] This present invention relates to improved methods and apparatus for delignifying and discharging the delignified cellulosic materials from a Batch Digester during and at the end of a pulping or cooking step.
[0002] In conventional batch pulping operations, the wood material (softwoods, eucalyptus, or hardwoods) or the lignocellulosic crop material (e.g., bagasse, bamboo, kenaf, reeds, and so forth) is reacted with cooking liquor for a given time at a specified temperature. The cooking liquor may be any of kraft, soda, alkaline, sulfite, polysulfide, or modifications thereof, such as with anthraquinone. At the desired terminating point of the delignification reaction, the cooked material still resides at high pressure and high temperature inside the digester.
[0003] Conventional Batch Reactors (digesters) used for producing fibrous cellulose from fiber bearing sources, such as wood, have traditionally been filled with the wood chips and cooking chemicals required to liberate the cellulosic fiber. Recently, new processes have emerged that reuse stored liquors (spent liquor) from the previous batch cooks to save energy and to take advantage of the residual chemicals in the spent liquor. Some of these new types of digesters require that 1) the reuse of spent liquor is pumped into the bottom of the digester with the excess liquor exiting out the top of the digester (hence they are referred to as Displacement Batch Digesters) and 2) the contents of the digester after delignification must be pumped from the bottom of the digester with gravity as the only pressure available inside the digester during most of the discharging operation feeding the discharge pump.
[0004] In order for all the contents of the digester to have the same chemical activity and to produce consistent quality pulp, the liquor that is pumped into the bottom of the digester must flow upward in a plug flow (i.e. no channeling) fashion. The fluid dynamics of this type of arrangement favors the rising liquors to follow the path of least resistance which is to flow against the smooth outer digester walls instead of flowing uniformly through the chip bed. Therefore, the rising fluid tends not to form a plug flow profile and the contents of the digester are not exposed to the same chemicals and temperatures.
[0005] Conventional Batch reactors (digesters) used for producing fibrous cellulose from fiber bearing sources, such as wood, have traditionally been emptied by opening the hot pressurized vessel to an atmospheric tank. This process is referred to as a “blow” and the atmospheric tank is referred to as a “blow tank”. Recently, new processes using batch digesters have been developed to remove the hot liquor from the pressurized digester before the “blow” thereby cooling the contents which precludes the violent flashing that occurs from high temperature liquor flashing into a blow tank from a pressurized vessel. The processes have been commercialized by various companies and are marketed under trade names such as RDH, Superbatch, CBC and DDS. Since the cooled digester does not have pressure and thermal energy to flash (blow), the contents (the product pulp fiber) must be pumped out of the digester in what is sometimes referred to as a discharge operation.
[0006] The discharging of the cooled digester contents is very difficult because the material in the digester, the product cellulose fiber, does not flow smoothly due to the pulp's inherent thixotropic properties. This also occurs because the fibers in the pulp may clump together and the black liquor in the pulp can easily separate from the mixture leaving behind fibers stuck inside the digester.
[0007] The commercial systems use nozzle jets at the bottom of the digester to spray fluid into the pulp mass in order to direct and maintain the flow of pulp with liquor out of the digester. The spray nozzles may be placed so as to create a circular flow of liquor in the digester. The flow out of the digester must exit through a “drain” opening at the bottom of the digester by gravity alone in an operation very similar to draining of a sink or tub of water. Unfortunately, a vortex forms due to the earth's rotation which interferes with the flow into the drain opening (outlet flange). The vortex in a large vessel such as a digester becomes substantial and the air funnel in the middle of the vortex can block 50% or more of the drain opening which greatly interferes with the draining process.
[0008] U.S. Pat. Nos. 4,814,042; 6,719,878; 5,800,674; H1,681; 4,764,251; 4,849,052; 6,306,252; 6,346,166; 6,346,167; 6,350,348; 6,391,628; 6,451,172 and 6,514,380 disclose various aspects of the delignification (cooking) process for providing wood pulp including the removal of the delignified pulp from the digester.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention pertains to methods and modifications to a Displacement Batch Digester to facilitate in-flow of pulping liquors through the material being pulped or cooked and the removal of cooked (delignified) pulp from any type of batch digester. The methods involve introducing liquid or liquor adjacent the bottom of the digester to accomplish a plug-flow regime in the digester during the cooking or pulping phase and also to introduce liquor during the discharge phase.
[0010] The apparatus of the invention involves modification to the digester to facilitate introduction of the wash out liquor (liquid) into the digester to assist in the discharging of the pulp. An overhead shower can be used to aid in emptying the cooked material. Mechanical devices can also be placed in the lower digester area to aid in removing the cooked pulp.
[0011] Therefore, in one aspect the present invention is a method of discharging delignified cellulosic material from a cooled Batch Digester at the end of a cook cycle, after removal or cooling of the hot liquor in the digester, comprising the steps of; introducing a shower of clean out liquor into the digester at a location above the material, the shower distributing the liquor substantially evenly across a cross-sectional area of the digester, and withdrawing the pulp from the digester while maintaining a flow of liquor sufficient to maintain consistency of the pulp until said digester is empty.
[0012] In another aspect the present invention is a batch digester of the type having a generally cylindrical section and a bottom generally conical section the conical section having an outlet located proximate the apex of the conical section, the improvement comprising; installing a distribution channel for liquid inside the digester at a location proximate a transition from the cylindrical section to the conical section, the distribution channel installed adjacent an inner surface of the digester and having means to direct a plurality of streams toward a vertical center line of the digester.
[0013] In yet another aspect the present invention is a batch digester of the type having a generally cylindrical section and a bottom generally conical section the conical section having an outlet located proximate the apex of the conical section, the improvement comprising; a plurality of distribution channels on the inner surface of the conical section the distribution channels extending from proximate where the conical section meets the cylindrical section to proximate the outlet, the distribution channels containing means to direct a plurality streams of liquor toward a vertical center-line of the digester.
[0014] In still another aspect the present invention is a method for enhancing plug-flow of pulping liquors introduced into a batch digester for delignifying cellulosic materials comprising the steps of: introducing a plurality of streams of the pulping liquor proximate a bottom location of the digester, the streams oriented to flow in a direction generally parallel to a vertical axis (up or downward flow) of the digester; and continuing flow of the liquor until the cellulosic material is delignified to a desired delignification.
[0015] In still another aspect the present invention is a method for enhancing plug-flow of pulping liquors introduced into a batch digester for delignifying cellulosic materials comprising the steps of: introducing a plurality of streams of the pulping liquor proximate a bottom location of the digester, the streams oriented to flow in a direction generally parallel to a vertical axis (up or downward flow) of the digester; and continuing flow of the liquor until the cellulosic material is removed from the digester.
[0016] In still a further aspect the present invention is a method of enhancing plug flow of pulping liquor introduced into a bottom of a batch digester for counter-current flow through a charge of cellulosic material to be delignified comprising the steps of: placing a flow directing device in the digester at a location proximate a bottom portion of a vertical portion of the digester, the flow directing device causing the pulping liquor to flow in a direction generally vertical to a center line of the digester; and containing flow of the liquor until the cellulosic material is delignified to a desired delignification.
BRIEF DESCRIPTION OF THE DRAWING
[0017] FIG. 1 is a schematic representation of a conventional system used to introduce cooking liquor into a batch digester.
[0018] FIG. 2 is a schematic representation of two different methods and apparatus to facilitate introduction of cooking liquors into cellulosic material during the cook in a Batch Digester.
[0019] FIG. 3 a is a schematic representation of a method and apparatus to facilitate removal of cooked pulp from a Batch Digester.
[0020] FIG. 3 b is a schematic representation of a device to aid the method and the apparatus of FIG. 3 a.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIG. 1 a batch digester 10 is used to pulp or cook lignocellulosic material. As part of the cooking process cooking liquor represented by arrow 12 is introduced into the bottom of Digester 10 and forced under pressure to flow upwardly through the lignocellulosic material shown as 14 . Although the intent is to have the cooking liquor move in a plug flow regime, in practice this does not happen. In fact arrows 16 , 18 illustrate the flow path of liquor inside the digester and line 20 illustrates the resulting flow pattern of liquor inside digester 10 . As stated above this condition leads to inconsistencies in the pulp/chemical interface and problems in removing cooked pulp from the digester.
[0022] According to the present invention three modifications can be made to a Displacement Batch Digester to mitigate the problems discussed above. The first is a liquor distribution channel placed at or above the bottom tangent (knuckle) line of the digester. The second is the use of liquor distribution channels placed on the bottom of the digester cone to distribute liquor and to help mitigate the formation of a large vortex during discharge or to inject liquors to entice plug flow. The third is to add a top shower head to keep the pulp on the top of the discharging mass diluted and to break up the flocs (which has been tested).
[0023] As shown in FIG. 2 a generally circular or toroidal distribution channel or pipe 22 is put inside the digester 10 at or above the digester tangent or knuckle line 26 . The tangent or knuckle line 26 is the location where an upper generally cylindrical portion 11 of digester 10 is joined to a lower or generally conical section 13 . A pipe, man-way or outlet 15 is placed at the apex of the conical section 13 of digester 10 . The channel 22 is constructed so that cooking liquor is pumped into the digester in generally vertical streams across the lignocellulosic material as shown by arrows 24 . A minor portion of the liquor flowing into channel 22 , as shown by line 23 , is withdrawn and introduced into the digester through outlet 15 as shown by line 30 . The channel 22 could also be put at a lower position in the digester 10 . The liquors flowing into the digester inside channel 22 will be distributed through perforations in channel 22 selectively located towards the center of the digester 10 as shown as 22 a. That is, the channel will have perforations towards the center line of the digester to allow the inflow liquor to exit the channel towards the center of the digester. A small percentage of the liquors put into channel 22 are permitted to exit the distribution channel 22 via line 30 and be directed into the bottom of the digester 10 in the traditional method used today for displacement type cooking. The liquor entering channel 22 will perform two functions: one, it will keep the channel 22 clear of deposits and unwanted debris and two, it will allow treatment of the material located below the distribution channel 22 and above outlet 15 . The distribution channel can be one or more pieces that could form several spokes. However, due to obstruction inside the digester, more than two channels (i.e. a simple cross pattern) is not suggested unless the digester diameter warrants it.
[0024] FIG. 2 also illustrates an alternate embodiment of the invention where two or more liquor channels 34 , 36 can be placed on the inner surface of the conical portion 13 of digester 10 . Channels 34 , 36 will extend from a location proximate the tangent 26 to a location proximate the discharge outlet 15 . Perforations or holes will enable liquor introduced into channels 30 , 32 to exit in a generally vertical direction as shown by arrows 38 , 40 . As opposed to the embodiment discussed above, all of the liquor will be introduced into channels 34 , 36 individually or via a common inlet. More than two channels 34 , 36 can be used, depending upon the size, etc. of the digester.
[0025] As shown in FIG. 2 the arrangement of the channels according to the invention will result in plug flow pattern through the lignocellulosic material or batch 14 inside the digester as illustrated by line 42 .
[0026] Referring to FIG. 2 the liquor channels 22 , 34 , 36 placed at the bottom of the digester 10 can be pipes, conduits or hollow channels to allow liquor flow into the digester through perforations or holes. The liquor channels could be used to dilute the pulp while the pulp passes the metal channels. The channels would be connected to a liquor supply pipe(s). Radial liquor channels or solid bars would also minimize the creation of a large vortex that interferes with the draining of the digester by dissipating the kinetic energy of the swirling liquor in the bottom of the cone. Creating obstructions on the smooth interior surface of the cone by placing channels therein would also help to improve flow of pulped material out of the digester.
[0027] Referring to FIG. 3 a batch digester 50 would be fitted with a pipe shown as 52 to inject liquor into the top of the digester. The liquor would exit the pipe 52 through a distribution shower head 54 to evenly distribute the liquor over the digester's cross sectional area as shown by arrow 56 . This flow of liquor would maintain the proper consistency in the pulp that is the last to exit the digester (the pulp floating and coagulating on the top of the digester contents) which is also the most probable to be “dewatered” as the discharging operation progresses. Further, as the level of the pulp in the digester decreases, the liquor from the shower head will have a greater distance to fall which increases it's kinetic energy. This momentum in the liquor must be dissipated into the pulp (as a force due to the change in momentum) which helps to break apart the pulp flocs and increase the flow out of the digester. This method and apparatus has been successfully tried at a commercial installation. In place of channels 22 , 30 , 32 solid members which would not distribute liquor but would act only as an energy dissipation device to minimize the creation of a large vortex during the draining of the digester can be used.
[0028] Obstructions attached to the bottom conical section of the digester will dissipate the circular fluid energy and mitigate the creation of a large interfering vortex. Such devices can be in the form of anti-vortex vanes 60 shown schematically in FIG. 3 b. The vanes would be placed on the inside surface of the conical section 51 of digester 50 extending from a location proximate the bottom tangent 53 to a location proximate the outlet 58 of digester 50 as sown by lines 60 in FIG. 3 a. The digester will drain in a shorter time due to the absence of a vortex by making available the full area of the drain opening as well as creating less foam from air being entrained into the liquor. The anti-vortex vanes could increase in height normal to the digester shell as the distance to the center drain opening decreases or any other configuration (e.g. constant height). Anti-vortex vanes are constructed to end at the drain opening as illustrated schematically in FIG. 3B . Additionally, the anti-vortex vanes could be made in the form of a hollow channel with openings or passages on the surface of the channel facing upwardly in the digester to allow liquor to be injected into the digester at any phase of the cooking operation (e.g. discharging or liquor charging).
[0029] Having thus described my invention what is desired to be secured by Letters Patent of the United States is set forth in the appended claims which should be read without limitation.
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Method and apparatus for introducing liquors into a batch digester to produce enhanced or plug-flow of the liquors through the bed of cellulosic material. Wash out liquor can be introduced into the digester during the discharging in a manner to add wash out liquor into the digester and to prevent formation of a vortex of material during discharge.
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BACKGROUND OF THE INVENTION
Chroma-key circuits are well known in the broadcast industry. By the use of such circuits it is possible to transmit composite pictures which alternately use the outputs from two separate cameras. For example, a street scene may be transmitted wherein the face of an announcer may be compositely placed in one corner to form the composite picture. Also, the composite presentation may depict an action scene appearing as the background of the picture, with the announcer standing the midst of the action scene.
Chroma-key techniques are used to affect such composite broadcast signals, for example, by placing the announcer in front of a single-color backdrop, and by sensing changes in the output from the announcer's camera to develop an output signal for switching between the announcer's camera and the action camera. For example, whenever the single-color backdrop is picked up during the sweep of the announcer's camera, the synchronized sweep of the action camera output is transmitted; while the output from the announcer's camera is transmitted whenever there is an absence of the backdrop color during the sweep of the announcer's camera.
A conventional method of chroma-keying utilized by the broadcast industry is to sense the ratio between the red, green and blue output signals from the announcer's camera, and when these ratios correspond to a predetermined value the chroma-key circuit operates to key the action camera. An absence of the predetermined ratio will cause the circuit to key the announcer's camera. The ratio should be a linear relationship, and the circuitry necessary to determine the linear relationships between the various colors and to generate the keying signal used to switch between the two cameras is quite complex and therefore expensive. Furthermore, cameras produced by some manufacturers do not provide separate red, green and blue output signals wherefore the conventional chroma-key circuit described above cannot be used without additional demodulating circuits. One patented example of circuitry which processes the three individual color signals is described in U.S. Pat. No. 3,678,182.
Accordingly, an object of the present invention is to provide a less complex chroma-key circuit capable of utilizing the standard composite NTSC signal which is generated by most known color cameras in the United States.
SUMMARY OF THE INVENTION
In accordance with the present invention, the standard NTSC signal from the keying camera is fed through a filter wherein the chrominance portion of the signal is isolated for application to a signal shaping circuit. The shaping circuit converts the sine wave chrominance signal into a square wave which is more adaptable for processing by conventional TTL techniques. The chrominance signal will have a certain phase relationship with respect to the E B' -E Y' phasor, depending on the color it is intended to represent. A phase reference signal is produced by a standard generator and the phase of that reference signal is adjusted to be identical to that of the background chrominance signal from the keying camera. The shaped reference signal and chrominance signal are then applied to an AND circuit which provides an output whenever there is coincidence between the two signals. From the above description it is seen that such coincidence will exist and will be maximized whenever the keying camera is sweeping past the single color backdrop.
One well known phase detecting technique, utilizing an AND circuit, functions to determine the desired coincidence by utilizing several comparisons from the AND circuit, and by generating a DC voltage which increases with an increase in coincidence time. This conventional technique is not utilized in the present invention, however, wherein a high speed detection of the coincidence is required.
In the present invention, a unique timing circuit is provided for timing the period of coincidence between the chrominance signal and reference signal. That is, a one-shot is triggered at the beginning of coincidence between the reference and chrominance signals, and the output of the AND circuit together with the output of the one-shot are applied to a clocked astable flip flop, wherein the clock signal is derived from the one-shot. Accordingly, the clocked flip flop senses the relative durations of the one-shot output and the AND circuit output to determine which of those outputs terminates first. If the AND circuit output lasts longer than the pre-determined period of the one-shot, thus indicating that the keying camera is sweeping past the single-color backdrop since the two signals feeding the AND circuit are in phase, then the keying signal causes the output from the action camera to be transmitted. A shorter AND circuit output will cause the keying camera output to be transmitted, since the two AND inputs are then out of phase, thus indicating that the keying camera is sweeping past the object which is to be compositely placed in the picture.
In addition to these general principles of the invention there is also disclosed a circuit for controlling undesired fringing effects. The term "fringing effects" relates to the imperfections which are noticed along the border of the object which is being keyed. A circuit for preventing such objectionable fringing characteristics operates by delaying the output of the keying signal by utilizing the luminance portion of the NTSC signal to control the output of the clocked flip-flop. In this manner the circuitry precludes false triggering of the keying signal, since that signal is initiated in response to the luminance signal which most accurately corresponds to the lines of separation between the object and the backdrop sensed by the keying camera. The luminance signal is passed through a differentiator which generates a pulse at every sharp increase or decrease of the luminance signal. A predetermined minimum amplitude of the differentiated signals is utilized as a clock pulse and applied to control the timing of the keying signal generated by the above described clocked flip-flop. The selected differentiated signals are applied through a delay line to prevent an otherwise segmented appearance which results from the digital techniques utilized for comparing the phase of the chrominance signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The principles of the present invention will be described in conjunction with a preferred embodiment depicted in the accompanying drawings. In such drawings:
FIG. 1 is a block diagram indicating the functional relationships of the elements in a preferred embodiment of the invention;
FIG. 2 is a schematic diagram of the digital selection circuit illustrated in FIG. 1;
FIG. 3 is a diagram illustrating a circuit for preventing objectionable fringing effects which may otherwise occur in a composite T.V. picture; and
FIG. 4 is a timing diagram depicting the relative operating times of the circuit elements shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The broad principle of the present invention, as depicted in FIG. 1 of the drawings, resides in the controlled switching between two T.V. camera outputs to provide a composite output to a transmitter 10. By synchronizing the sweeps of the two cameras, it is possible to thereby alternately transmit the output from a "scene" camera 12 to form one portion of a composite signal, and to transmit the output from a "keying" camera 14 to form another portion of that composite signal. The selection of camera outputs by a switch 16 is controlled by a digital selection circuit 18 which senses phase changes in an NTSC output from the keying camera. To this end, the NTSC output from the keying camera 14 is applied through a filter 20 to the digital selection circuit 18, together with a second input applied to the circuit 18 from a reference generator 22. For timing purposes, the respective camera outputs are coupled to the switch via delay lines 12a and 14a.
In accordance with color television technology as practiced for example in the United States, color cameras provide a compatible output signal which is designated as an NTSC signal, and which is expressed as:
E.sub.M' = E.sub.Y' + E.sub.I' cos (wt + 33°) + E.sub.Q' sin (wt + 33°)
In the above equation, the quantity E Y' is referred to as the "luminance" portion of the signal, while the remaining two quantities define the chrominance portion of the signal. The NTSC signal is derived from the following equations:
E.sub.I' = 0.30E.sub.R' + 0.59E.sub.G' + 0.11E.sub.B'
e.sub.i' = 0.60e.sub.r' - 0.28e.sub.g' - 0.32e.sub.b'
e.sub.q' = 0.21e.sub.r' - 0.52e.sub.g' + 0.31e.sub.b'
wherein the quantities E R' , E G' , and E B' , are related to the red, green and blue colors sensed by the camera.
The chrominance portion of the signal E M' , as defined above, may be expressed as a phase angle dependent upon the hue of the NTSC signal. That phase angle is defined by the equation:
φ = arc tan [(1.78 (E.sub.R' - E.sub.Y' /E.sub.B' - E.sub.Y'))]
accordingly, it is seen that the NTSC signal may be expressed, at any instant, by an amplitude, the luminance portion of the signal, and a phase angle φ indicating the proper color to be reproduced at that instant.
It is known that the color blue occupies a large angle of the 360° continuum of colors provided by the phase angle φ and therefore it is preferable to use the color blue as the backdrop for the keying camera. Accordingly, the backdrop is preferably selected to provide a phase angle φ within the range of blue colors which are centered at 300°.
As illustrated in FIG. 1, the above described NTSC signal from the keying camera is applied through the filter 20 to a signal shaping circuit 24. The filter 20 may constitute a comb filter, or a filter such as presently embodied in commercial color T.V. receivers and adaptable for use in isolating the chrominance signal from the NTSC signal. The signal shaping circuit 24 may comprise for example a Signetics 521 dual comparator-inverter device, wherein the chrominance signal from the filter 20 is applied as an input to one of the comparators 24a, while the reference signal from the generator 22 is applied as an input to the other comparator 22b. Fixed signals are applied to the other inputs of each of the two comparators for use in generating shaped output signals, and these interconnections are shown also in FIG. 2 of the drawings which shows the details of the digital selection circuit 18. The reference signal generator 22, having its output applied to one of the dual comparators, may constitute a special effects generator for providing a reference signal having a phase corresponding to the color background sensed by the keying camera, and it may be applied through an adjustable phase shifter. That is, the phase of the reference signal is adjusted to correspond closely to the phase of the chrominance signal related to the backdrop of the keying camera. The outputs of the dual comparators are applied respectively through inverters 24c and 24d as inputs to an AND circuit 28. The output of the AND circuit 28 is applied through two series connected inverters 30 and 32 to an input of a clocked flip-flop 34. In this regard, the clocked flip-flop 34, as illustrated in FIG. 2, may comprise one half of an IC device N74S113 which constitutes a dual JK flip-flop chip, wherein the output from the inverter 32 is coupled to the J input of the device 34. The output of the inverter 30 is applied also as an input to a one-shot multivibrator 36 which may constitute for example an IC device 9601. The period of the one-shot may be controlled, for example, by an external variable resistance circuit 38 connected thereto. The output of the one-shot is applied through an inverter 40 to the K input of the JK flip-flop 34, while the clock input CK to the JK flip-flop is also supplied through an AND circuit 42 and an inverter 44 from the output of the one-shot 36 and from the inverter 30.
In the operation of the circuitry thus far described, the chrominance portion of the NTSC signal from the keying camera, produced by the backdrop color, is converted into a square wave by the signal shaping circuit and is provided as one input to the AND circuit 28, along with a square wave shaped signal from the reference signal generator 22. As shown in FIG. 2a, an output from the AND circuit 28 results whenever there is coincidence between the reference and chrominance signals. The one-shot circuit 36, in effect, then times the duration of coincidence to determine whether it is in excess of a predetermined minimum. That is, the coincidence signal from the AND circuit 28, when passed through the first inverter 30, is applied to the one-shot 36 to initiate its timed "on" period. Also, the output from the inverter circuit 30, is applied through the inverter circuit 32 to the J input of the clocked flip-flop 34, while the output of the one-shot is applied to the K input to the clocked flip-flop. The period of the one-shot 36 is set to correspond to a predetermined minimum desired coincidence period, so that when the phase of the chrominance signal is sufficiently close to the phase of the reference signal, the coincidence period will exceed the period of the one-shot, but when the coincidence time is less than the period of the one-shot the J input to the flip-flop will disappear before the termination of the K input thereto. The set up time for the JK flip-flop designated above is 3 ns and when the clocking signal terminates to end the enabling period of operation of the JK flip-flop 34, the output thereof will be controlled to indicate which of the inputs, J or K, terminated first. Also, as is apparent in FIG. 2 of the drawings, the termination of the J or K input is the function which terminates the clocking pulse since the clocking signal output from the AND circuit 42 and the inverter circuit 44 is controlled by the outputs from the AND circuit 28 and one-shot 36. In operation, during the pickup of background signals by the keying camera, the output from the AND circuit 28 will always have a duration exceeding that of the one-shot so that the output from the action or scene camera will be coupled to the transmitter in response to the output from the JK flip-flop which controls the switch 16. Similarly, when the duration of the one-shot 36 is sensed as exceeding the duration of the coincidence signal from the AND circuit 28, the output from the JK flip-flop will cause the transmission of the signal from the keying camera.
It may be desirable to include a third quantity in a composite signal wherein for example an announcer appears in an action scene together with an identifying legend defining the location of the action scene. Furthermore, it may be necessary that the background for the legend have an absence of color whereby the chrominance signal from the keying camera will go to zero when the sweep passes that colorless background. From the above description of the invention it is seen that the absence of a chrominance signal at the input to the amplifier and pulse shaper 24 will preclude any output from the AND circuit 28, so that the JK flip-flop will remain in its previously set state and will not change even though the sweep of the camera passes out of the desired blue area. To render the circuit functional even under the conditions of a colorless portion of the backdrop, there is provided a dual monostable multivibrator 46 illustrated in FIG. 2. The dual multivibrator device may comprise an IC N74123 chip, wherein the chrominance signal from the pulse shaper circuit 24a is applied as an input to each section, and wherein the output is used as a pre-set input to the second half 48 of the JK flip-flop 34. In the operation of this device, the output from the chrominance pulse shaper circuit 24a triggers one stage 46a of the monostable multivibrator, wherein that stage has a period in excess of one cycle of the chrominance signal. Accordingly, the output of that stage of the dual monostable multivibrator remains "on" continuously whenever a color signal is sensed by the keying camera. But, when a color signal is not sensed by the keying camera during its sweep for more than the period required for a complete cycle of the chrominance signal, then the output of the first stage 46a is switched to its "off" condition, and since the output of that first stage is applied through a NAND circuit 50 and an invertor 52 to the pre-set input of the second JK flip-flop 48, that flip-flop is disabled so that the switching circuit 16 couples the keying camera output to the transmitter. The JK flip-flop 48, as will be understood from the schematic of FIG. 2, provides a one cycle delaying function necessitated by the delayed sensing of cessation of the chrominance signal.
When the sweep of the keying camera passes from the gray background to the blue backdrop, the chrominance signal again triggers the first stage 46a of the one-shot which applies its "on" output to the NAND circuit 50. However, to maintain proper synchronization it is necessary to again delay the output of the JK flip-flops one cycle, and for this purpose the second half 46b of the one-shot chip has a period slightly less than one complete cycle of the chrominance signal, and has its Q output connected to the NAND circuit 50 so that output does not reach an "on" condition until just prior to the completion of one cycle of the chrominance signal. But when both inputs to the NAND circuit 50 are in their "on" condition, the pre-set input to the second JK flip-flop 48 again enables that circuit. The second one-shot circuit 46b has its Q output maintained in its "on" condition by means of a feed back loop from the output of the NAND circuit to the input to the circuit 46b as illustrated in the drawing.
In the operation of the invention thus far described, it will be understood that the interface between the backdrop and the keying object may produce a stair-step or fringing effect. This phenomenon, sometimes referred to as "crawling" is caused when the interface between the backdrop and the object shifts from one frame to the next along a single scan line. To compensate for objectionable fringing displays, a circuit is provided, as depicted in FIG. 3, wherein the luminance signal which may be isolated by the filter 20 is applied to a differentiating circuit 54 for providing an output signal in response to sharp changes in the luminance signal. The output of the differentiator circuit 54 is applied to a comparator 56 for providing an output whenever the differentiated signal exceeds a predetermined reference level. The output of the comparator 56 is then applied through a delay line 58 and an inverter 60 to the clocking input of a third JK flip-flop 62, wherein the output of the second JK flip-flop 48 provides the inputs to the third circuit 62 and wherein the output of the third circuit 62 may comprise the last stage of the digital phase comparator for controlling the switch 16.
In the operation of the circuit shown in FIG. 3, for preventing objectionable fringing, the effects of the digital timing are overcome by using the differentiated pulse resulting from a large variation in the luminance signal, wherein that large variation corresponds to an "edge" in the chrominance signal. Accordingly, as depicted in the timing diagram shown in FIG. 4, the switch 16 will be controlled to cause the display of the keying camera output at the same time during corresponding scans in successive frames since the differentiated luminance signal, corresponding to the raw output, is utilized as the switching control signal, and since that differentiated signal is delayed for a time sufficient to insure the presence of an output from the second JK flip-flop.
High speed devices are believed to be preferable for use as all of the independent AND and inverter circuits which are illustrated in the drawings and used in conjunction with the integrated circuit devices discussed herein. For example, in a preferred embodiment, the AND gates may constitute portions of N74S00 IC devices, while the inverters may constitute N74S04 IC devices.
It is to be understood that the foregoing detailed description of circuitry disclosed herein is directed toward a preferred embodiment of Applicant's invention, but that such invention is not limited to the specifically disclosed circuitry, and that the invention encompasses modifications which fall within the terms of the claims set forth herein.
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A chroma-key circuit is described for use in alternately selecting one of two TV camera outputs to provide a composite picture, wherein the selection is controlled by detecting changes between a background color and an object color sensed by one of the two cameras. Keying is accomplished digitally by comparing the phase of the chrominance signal from the one camera with the phase of a reference signal, and by switching the circuitry to transmit the signal from the one camera only when the chrominance and reference signals are out of synchronization.
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INVENTION BACKGROUND
High Pressure High Temperature (HPHT) wells necessitate a requirement to bleed down casing string annuli, to prevent thermal pressure loads from damaging the completion casing program. Thermal expansion of trapped fluid in the casing annuli could otherwise lead to excessive pressure build up causing damage to or failure of the casing completion system.
Annulus bleed down can be readily achieved on surface wellhead applications, as the wellhead housing can be provided with annulus outlets. Subsea wellheads do not have annulus outlets. Each casing string is instead suspended and sealed within the wellhead high pressure housing. No provision is made for communication between each casing string annulus and the wellhead exterior. Assuming that it would be possible to extract annulus fluid as and when required, there is the further problem of disposing of the bled off fluid in an environmentally acceptable way. With the introduction of HPHT completions into the subsea environment, there is a need for subsea wellheads that can facilitate annulus bleed downs.
SUMMARY OF THE INVENTION
According to the present invention, a subsea wellhead comprises a monitoring and/or bleed down port extending laterally through a wall of the wellhead housing and having an interior end connected to a well annulus and an exterior end connectable to a jumper for conveying pressure signals and/or expelled annulus fluid to a controls interface.
A preferred embodiment of the invention facilitates the isolation and pressure monitoring of each casing annulus, via a remotely deployable electro/hydraulic control jumper providing a link between the wellhead casing annuli and the subsea production control facility, or a workover control system, as desired. The invention may be used with particular advantage in conjunction with a drill-through horizontal Christmas tree.
The preferred embodiment makes use of three primary components.
1. A modified subsea wellhead housing containing linked annulus ports.
2. A bolt on valve block incorporating independent isolation valves, pressure monitoring equipment and an electro/hydraulic control interface. Alternatively, some or all of these components may be integrated into the wellhead itself.
3. An ROV/diver deployable electro/hydraulic control stab plate jumper to facilitate remote connection between the subsea production control system and the wellhead electro/hydraulic control interface.
Further preferred features of the invention are in the dependent claims and in the following description of an illustrative embodiment made with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of a wellhead embodying the present invention;
FIG. 2 is a more detailed view of the wellhead of FIG. 1;
FIG. 3 is a view on arrow III in FIG. 2;
FIG. 4 is a front view of an ROV plate of the wellhead;
FIG. 5 is a view from behind the ROV plate of FIG. 4 and
FIG. 6 shows an ROV deployed jumper.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a wellhead housing 10 in which is landed a first casing hanger 12 , a second casing hanger 14 and a tubing hanger 16 . The wellhead housing 10 is mounted on an outer casing 18 and the casing hangers 12 , 14 suspend casing strings 20 , 22 respectively. Tubing 24 is suspended from the tubing hanger 16 . A first annulus 26 is defined between the tubing string 24 and the casing string 22 ; a second annulus 28 is defined between the casing strings 22 , 20 and a third annulus 30 is defined between the casing string 20 and the outer casing 18 . A first annulus port 32 is formed extending through the wall of the wellhead housing 10 , having an inner end in communication with the space below the casing hanger 20 and hence in communication with the outermost annulus 30 . A second annulus port 34 is formed extending through the wall of the wellhead housing 10 , having an inner end in communication with the space defined between the casing hangers 12 and 14 , and hence in communication with the production casing annulus 28 . A third annulus port 36 is formed extending through the wall of the wellhead housing 10 , having an inner end in communication with the space defined between the tubing hanger 16 and the production casing hanger 14 , and hence in communication with the tubing annulus 26 .
The outer ends of the annulus ports 32 , 34 , 36 are connected to hydraulic couplers 38 , 40 , 42 contained in a valve block 44 bolted to the wellhead 10 . Each annulus port connection within the valve block 44 is controlled by a respective ROV or diver operable isolation valve 46 , 48 , 50 and is equipped with a pressure transducer 52 , 54 , 56 . An ROV/diver deployable electro-hydraulic jumper 58 is connectable to the valve block 44 to convey expelled annulus fluid from the hydraulic couplers 38 , 40 , 42 to a production controls system or workover controls system (not shown), as appropriate. Electrical couplers 60 , 62 , 64 are provided in the valve block 44 and mate with corresponding jumper connectors 66 , 68 , 70 for conveying pressure signals to the production or workover controls system. When the pressure reading from one of the transducers 52 , 54 , 56 exceeds a critical value, the corresponding valve 46 , 48 , 50 can be opened, allowing annulus fluid to be vented or bled off into the production or workover controls system, so reducing the annulus pressure and avoiding damage to the casing completion program. During well drilling operations, the jumper 58 can be disconnected and replaced by a protective cap.
FIGS. 2-6 show the wellhead 10 , valve block 44 and jumper 58 in more detail. The wellhead housing 10 is supported in a conductor housing 72 welded to the upper end of a conductor casing 74 surrounding the outer casing 18 . The annulus ports 32 , 34 , 36 are drilled vertically downwardly through the wall of the housing 10 from its upper surface 96 , at circumferentially spaced locations. The upper ends of the vertical drillings are then plugged. Radial drillings 76 , 78 , 80 provide communication between the wellhead interior and the respective vertical drillings, at the correct vertical locations for communication with the respective casing/tubing annuli. Further horizontal drillings 82 , 84 , 86 in the valve block 44 and wellhead housing 10 communicate between the vertical drillings and the valves 46 , 48 , 50 . The pressure transducers also communicate with the horizontal drillings 82 , 84 , 86 . An ROV plate 98 (FIG. 4) is mounted to one end of the valve block 44 and contains ROV receptacles 100 , 102 , 104 for actuation of the valves 46 , 48 , 50 . Vertical drillings 88 , 90 , 92 lead from the valves 46 , 48 , 50 and are connected to the hydraulic couplers 38 , 40 , 42 mounted on the ROV panel, by hoses 94 . Electrical wet-mate connectors 62 , 64 , 66 on the ROV panel 98 are connected to the pressure transducers 52 , 54 , 56 by cables 106 . The electro/hydraulic jumper has corresponding hydraulic and electrical couplers arranged to mate with those in the ROV panel 98 in use.
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A subsea wellhead ( 10 ) includes annulus pressure monitoring and bleed down ports ( 32, 34, 36 ) whereby excessive pressure may be detected and bled off to a production controls or workover controls system via an electro/hydraulic jumper ( 58 ). A valve block ( 44 ) bolted to the wellhead ( 10 ) includes pressure transducers ( 52, 54, 56 ) and isolation valves ( 46, 48, 50 ). Excessive annulus pressures and hence damage to the completion program may thereby be avoided in HPHT subsea well applications.
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BACKGROUND OF THE INVENTION
This invention relates to a new process for making vicinal epoxides.
Vicinal epoxides are valuable chemical intermediates and monomers useful in making epoxy adhesives and various heat- and solvent-resistant polymers. A well-known process for making vicinal epoxides from olefins involves the oxidation of the olefinic double bond with aqueous chlorine to form the chlorohydrin and reaction of the chlorohydrin with a base to make the epoxide. However, a major disadvantage of this process is the production of an equivalent of HCl from the aqueous oxychlorination step and another equivalent of inorganic chloride from the reaction of the base with the chlorohydrin intermediate. In the case of epichlorohydrin, the conventional preparation uses the same chemistry with the added initial step of chlorinating propylene to allyl chloride which produces an additional equivalent of HCl.
Ethylene oxide is prepared by oxidizing ethylene with molecular oxygen over a silver catalyst. However, this method is not applicable to other olefins because of low selectivity and the formation of by-products. Another method using oxygen involves oxidizing a hydrocarbon such as isobutane or isopropylbenzene with air to the corresponding tertiary hydroperoxide and then reacting the hydroperoxide with an olefin in the presence of a transition metal catalyst. A disadvantage of this process is the formation of co-product alcohol which must be solid or recycled.
Hydrogen peroxide and peroxy acids are other reagents which have been used to epoxidize olefins. Chemical and economic disadvantages of such methods have precluded their use on a large scale.
It is known that cyclic carbonates can be decomposed to form epoxides in the presence of various catalysts. Such a process particularly directed to the preparation of propylene oxide by decomposition of propylene carbonate in the presence of a sulfonium or phosphonium halide or any of certain metal salts is described in U.S. Pat. No. 4,069,234.
SUMMARY OF THE INVENTION
It has now been found that vicinal epoxides of various kinds, not only the simple alkylene and cycloalkylene oxides, but also their aromatic and halogen-substituted derivatives, can be made in good yield by heating an unsymmetrical β-haloalkyl carbonate of the formula ##STR2## in the presence of a small but effective amount of a quaternary ammonium or phosphonium salt at a temperature of about 25° C.-250° C. The products of this decomposition are CO 2 , the halide R 5 X, and the epoxide of the formula ##STR3## wherein X is Cl or Br, each of R 1 , R 2 , R 3 , and R 4 is hydrogen, a hydrocarbon group, --CH 2 X, or R 1 and R 2 together form an alkylene group of 3-6 carbon atoms, and R 5 is an alkyl group, preferably a lower alkyl group.
DETAILED DESCRIPTION OF THE INVENTION
The term hydrocarbon group as used above to define R 1 , R 2 , R 3 , and R 4 includes alkyl groups of one to about 20 carbon atoms, cycloalkyl and alkylcycloalkyl groups of 5-10 carbon atoms, and aromatic hydrocarbon groups of 6-10 carbon atoms. R 5 is preferably a lower alkyl group as noted and is most preferably a methyl or ethyl group.
As can be seen from the above description, this process produces two useful products, the alkyl halide R 5 X and the epoxide, assuming CO 2 to be a waste product. The structure of the starting β-haloalkyl carbonate, therefore, is normally designed to produce not only the desired epoxide, but also a particular useful alkyl halide which has a boiling point sufficiently different from the epoxide to facilitate easy and complete separation of these two products.
The decomposition reaction takes place in the presence of the quaternary salt catalyst at some rate at any temperature from about room temperature to about 250° C., but for normally practical reaction times, the decomposition is preferably carried out at about 150°-250° C. Reaction times can range from 0.001 hour to about 10 hours depending on the structure of the carbonate, the temperature, and the nature and amount of the catalyst.
Substantially any quaternary ammonium or phosphonium salt can catalyze the decomposition reaction. Preferably, these salts have the general formula R 4 AY where each R is a hydrocarbon moiety; A is a quaternized nitrogen or phosphorus atom; and Y is an inert (i.e., inert in this process) neutralizing anion which may be inorganic, e.g., chloride, bromide, iodide, bicarbonate, sulfate, or the like; or Y may be an organic ion such as formate, acetate, benzoate, phenate, or bisphenolate. The R groups may be alkyl, aryl, alkaryl, aralkyl, or cycloalkyl. Also, two R groups may combine to form a heterocyclic ring. Illustrative quaternary salt catalysts are tetrabutylammonium bromide, benzyltriethylammonium chloride, N-methylpyridinium chloride, N,N-dibutylmorpholinium iodide, N-propylpyrrolium chloride, tetrabutylphosphonium bromide, tributylmethylphosphonium formate, tetrapropylphosphonium bisulfate, and corresponding ammonium and phosphonium salts with these and other such inorganic and organic neutralizing anions as described above.
Although any significant amount of such a quaternary salt will catalyze the decomposition reaction to some extent, for practical reasons in batch operations, it is preferred to use about 0.1-10 mole percent of the salt based on the carbonate. More quaternary salt catalyst can be used but the excess confers little added advantage and may in fact be disadvantageous.
In a mode of the invention particularly adapted to continuous operation, one or more R groups may be pendant methylene groups from a resin matrix so that the quaternary salt is a salt form of a strong base anion-exchange resin such as DOWEX® 21K, DOWEX® 11, DOWEX® MSA-1, or other such commercially available ion-exchange resins or the phosphonium equivalents of such quaternary ammonium-substituted resins. In such a continuous operation of the process, the β-haloalkyl carbonate starting material is passed at an appropriate flow rate through a bed of the strong base anion resin maintained at a suitable temperature within the limits previously defined.
A reaction solvent or diluent is usually of no advantage and the process is ordinarily run in the absence of such an inert additive. In some cases, however, a solvent may be of some advantage. Inert solvents suitable for use include hydrocarbons such as toluene, xylene, and decane; glycol diethers such as dimethyloxy ethane, substituted amides such as N,N-dimethylformamide, and cyclic compounds such as tetrahydrofuran and sulfolane.
In the preparation of higher boiling epoxides particularly, separation of the epoxide product may be facilitated by running the reaction under appropriately reduced pressure or by passing a stream of nitrogen or other inert gas through or over the reaction mixture.
The β-haloalkyl alkyl carbonate starting materials for this process can be prepared by any of several generally known procedures. Pechukas, U.S. Pat. No. 2,518,058 describes the reaction of an epoxide with a haloformate to make a corresponding β-haloalkyl alkyl carbonate. These mixed carbonate esters can also be made by the acid-catalyzed transesterification reaction of a halohydrin with a dialkyl carbonate. For example, 2-chloroethyl methyl carbonate is produced by the reaction of diemthyl carbonate with ethylene chlorohydrin and 1-chloro-2-propyl ethyl carbonate can be made by reacting diethyl carbonate with 1-chloro-2-propyl alcohol. Variations of this method can be used to make particular halogenated alkyl carbonate esters. Corresponding monohalo- and dihalopropyl carbonates, for example, can be made by first reacting allyl alcohol with a dialkyl carbonate and then adding hydrogen halide or halogen to the olefinic double bond in the allyl alkyl carbonate product.
EXAMPLE 1
A mixture of 4.57 g of 1-chloro-2-propyl methyl carbonate (contained 20-30 percent of the 2-chloro-1-propyl isomeric ester) and 0.034 g of tetrabutylphosphonium bromide in a 10 ml reaction flask was heated by an oil bath at 180° C.-185° C. for 2 hours. The flask was equipped with a magnetic stirrer, a condenser, and a receiver plus a trap, each of the latter containing 10 g of chloroform cooled to -60° C. After 2 hours of heating, the residue in the reaction flask amounted to 0.23 g of material which contained less than 5 percent starting carbonate. The receiver and trap had gained a total of 2.5 g of reaction products which were determined by nuclear magnetic resonance spectroscopic and chromatographic analysis to be a mixture of propylene oxide and methyl chloride, some methyl chloride having been lost because of its high volatility. The conversion of chloropropyl methyl carbonate was nearly 100 percent and the analyses indicated a yield of about 95 percent of the theoretical for propylene oxide.
EXAMPLES 2-3
The procedure of Example 1 was repeated twice using 0.027 g of tetrabutylammonium chloride and 0.037 g of tetrabutylammonium iodide respectively in place of the phosphonium salt catalyst. In each case, the yield of propylene oxide was 97-99 percent of the theoretical amount but the conversion of starting carbonate was relatively low, about 20 percent and 25 percent respectively.
EXAMPLE 4
The procedure of the above examples was repeated using 0.5 g of DOWEX® MSA-1 ion-exchange resin as the catalyst. The resin contained 40-50 percent water. This resin is a strong base anion resin consisting of a macroporous cross-linked styrene polymer matrix having pendant quaternary ammonium chloride functionalities. After 2.5 hours of heating time, about 99 percent of the carbonate had been decomposed to form 95 percent of the theoretical quantity of propylene oxide.
EXAMPLES 5-11
Other alkyl 1-chloro-2-propyl carbonates (containing 20-30 percent of the corresponding 2-chloro-1-propyl ester) were heated for 2 hours as described above to produce propylene oxide using different tetrabutylphosphonium salts as catalysts. Each carbonate was used in a quantity of 0.03 g mole. The results are summarized in Table I.
TABLE I______________________________________Example Alkyl Phosphonium Catalyst % %No. group Salt Wt. g. Conv. Sel.______________________________________5 ethyl bromide 0.034 2-3 996 ethyl bicarbonate 0.032 5-6 997 ethyl formate 0.030 35-37 998 ethyl bisphenate.sup.b 0.075 37-38 999 ethyl bisphenate.sup.b 0.215 98 96 10.sup.a n-propyl bisphenate.sup.b 0.215 99 95 11.sup.a isopropyl bisphenate.sup.b 0.215 39 93______________________________________ .sup.a Heating time was 6 hours. .sup.b Monosalt of Bisphenol A complexed with one molecule of the free bisphenol.
EXAMPLE 12
A mixture of 4.16 g of 2-chloroethyl methyl carbonate and 0.034 g of tetrabutylphosphonium bromide was heated at 180° C. for 3 hours in the apparatus previously described. A carbonate conversion of 99.7 percent was obtained with an 89 percent yield of ethylene oxide.
EXAMPLE 13
In the same way, a mixture of 5.49 g of 2-bromoethyl methyl carbonate and 0.034 g of tetrabutylphosphonium bromide was heated for 6 hours at 200° C. to produce a carbonate conversion of 100 percent and an 88 percent selectivity to ethylene oxide and methyl bromide.
EXAMPLE 14
Similarly, a mixture of 2.92 g of 1-chloro-2-hexyl methyl carbonate (containing 22 percent of the 2-chloro-1-hexyl isomer) and 0.024 g of tetrabutylphosphonium formate was heated at 200° C.-205° C. for 2 hours to produce an isolated yield of 98 percent of the theoretical quantity of 1,2-epoxyhexane.
EXAMPLE 15
A mixture of 3.34 g of 1-chloro-2-octyl methyl carbonate (containing 21 percent of the corresponding 2-chloro-1-octyl ester) and 0.024 g of tetrabutylphosphonium formate was heated as above at 200° C.-205° C. for 2 hours at reduced pressure (200 mm Hg). An isolated yield of 96 percent of theory of 1,2-epoxyoctane was collected in the receiver.
EXAMPLE 16
A mixture of 2.89 g of 2-chlorocyclohexyl methyl carbonate and 0.039 g of tetrabutylphosphonium salt of Bisphenol A (as used in Examples 8-11) was heated at 200° C.-205° C. for 1.5 hours. A yield of 1.34 g of 1,2-epoxycyclohexane was collected in the receiver.
EXAMPLE 17
In a procedure similar to that used in Example 15, a mixture of 3.89 g of 2-bromo-1-phenylethyl methyl carbonate and 0.024 g of tetrabutylphosphonium formate was heated at 180° C. for 2 hours at 50 mm Hg absolute pressure. The product condensed in the receiver was 1.58 g of a mixture containing 40 percent styrene oxide and 60 percent phenylacetaldehyde.
EXAMPLE 18
The reduced pressure technique of Examples 15 and 17 was followed in heating a mixture of 5.61 g of 1,3-dichloro-2-propyl methyl carbonate and 0.078 g of the tetrabutylphosphonium Bisphenol A salt used in Examples 8-11 and 16. After 2 hours at 195° C.-200° C. and 100 mm Hg absolute pressure, 2.85 g of 88 percent pure epichlorohydrin had condensed in the receiver.
EXAMPLE 19
To a 4-neck 50 ml reaction flask equipped with a mechanical stirrer, addition funnel, distillation head, and nitrogen inlet there was added 0.24 g of tetrabutylphosphonium formate and the flask was heated to 185° C.-190° C. with a stream of 30 ml/min. of nitrogen passing through while 2.81 g of 2,3-dichloro-1-propyl methyl carbonate was added over a period of 30 minutes. Analyses of 1.4 g of condensed effluent in the receiver cooled by solid CO 2 and 0.47 g of residue indicated a 90-95 percent conversion of carbonate with a 50-60 percent yield of epichlorohydrin.
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Vicinal epoxides are prepared by decomposing a β-haloalkyl carbonate of the general formula ##STR1## in the presence of a quaternary ammonium or phosphonium salt.
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BACKGROUND OF THE INVENTION
The present invention relates generally to the field of instruments for spectrally measuring and analyzing optical properties of samples. Such instruments are presently used in industrial and agricultural applications for colorimetry and for quantitatively analyzing the constituents of samples. Additional applications for such instruments are being developed in the field of medicine in which samples are spectrally analyzed for diagnostic purposes.
Examples of agricultural applications presently in use are instruments which accurately determine the oil, protein and water content in grain or soy beans. The traditional analytical laboratory techniques, such as the Kjeldahl technique for measuring protein, are extremely accurate but require the services of a skilled chemist. The results, furthermore, are not immediately or readily available. Buyers of agricultural products have demonstrated an increasing interest in accurate and rapid determinations of the moisture, protein and oil percentages of the various produces purchased. The wheat export market, for example, has seen the widespread introduction of selling on the basis of guaranteed protein content. This competitive pressure has increased the requirement of the commodity handler, from the country elevator to the export terminal, to rapidly and accurately sort grains and other products by their protein percentage, as well as by oil and water content, where applicable. The need for versatile, yet low cost, advanced equipment, which combines and improves upon recent scientific findings in the field of nondestructive testing of agricultural products has greatly increased. For maximum usefulness of commodity handlers, such an instrument must not place high demands on the skillfulness of the operator or require a specialized knowledge of the scientific basis for the end result.
Recent developments have provided instruments which are able to satisfy some of the above requirements of commodity handlers. The optical analyzer described by Donald R. Webster in U.S. Pat. No. 3,861,788, assigned to the assignee of the present application, provides an automatic test instrument for gauging the percentage of various constituents in organic substances by comparing the reflective optical density of the sample at various wavelengths. This device contains narrow band optical filters connected together in the form of a rotatable paddlewheel positioned so that the filters can be individually swept through the incident light path between the specimen and a wideband light source. As the filter wheel turns, the band of light passed by each filter is progressively shifted with the changing angle of the filter relative to the light path. The filter wheel configuration includes opaque vanes extending from the ends of the filters to periodically interrupt the passage of light to the specimen. Photodetectors are positioned to sense the level of light reflected from the specimen. The output of these photodetectors is sampled at predetermined times relative to the rotation of the filter wheel to yield values indicative of reflected intensity at certain wavelengths. An electronic circuit utilizes this data to calculate three optical density difference values corresponding to moisture, protein and oil content of the specimen sample. The difference values are automatically inserted into three linear equations which are solved to obtain readings representing the three percentages of oil, water and protein content of the specimen. Each time a new specimen is loaded for testing, the instrument described in U.S. Pat. No. 3,861,788 is automatically calibrated against a standard sample, preferably Teflon (trademark). The output of the photodetectors is amplified in a special circuit which subtracts the level of dark period current from the output when the photodetectors are illuminated.
A related, but earlier, instrument is described by Eugene R. Ganssle and Donald R. Webster in U.S. Pat. No. 3,765,775, entitled "Optical Internal Quality Analyzer", and also assigned to the assignee of the present application. The specimen sample therein is illuminated with light sequentially filtered by a continuously rotating disc carrying a plurality of narrow bandwidth optical interference filters. The combined output of several photodetectors positioned to receive light transmitted through or, alternatively, reflected by the specimen is selectively sampled after passing through a logarythmic amplifier to obtain readings at two discrete wavelengths which are then compared in a differential amplifier to provide the required measurments. Although the system described in U.S. Pat. No. 3,765,775 is satisfactory for its intended purpose, its ability to make readings at various wavelengths is naturally limited by the number of filters carried by the disc. It is, therefore, not possible to take readings at wavelengths between those of two adjacent filters. This limitation is mitigated somewhat by the filter wheel construction of the aforementioned U.S. Pat. No. 3,861,788.
Yet another recent prior art photo-optical technique for determining, for example, the fat content of meat is described by George F. Button and Karl H. Norris in U.S. Pat. No. 3,877,818 owned by the United States of America. This technique, developed at the U.S.D.A. Agricultural Research Service in Greenbelt, Maryland utilizes an instrument wherein a meat sample is exposed to infrared radiation from an incandescent light source. The radiation is transmitted through or reflected from the meat sample onto a tilting mirror which causes the respective transmitted or reflected light from the meat to pass through a planar interference filter at varying angles of incidence. Varying the angle of incidence of the filter by oscillating the tiling mirror produces a corresponding change in the wavelength of the radiation passing through the filter over a narrow bandwidth in the infrared spectrum. A photodetector receives the light transmitted through the filter and generates an electrical signal that is processed to read the fat content of the sample.
These and other prior art optical analyzers are limited in the accuracy of their measurements by the particular optical components and systems utilized for spectral analysis. The variety of agricultural products requiring very accurate content analysis has increased the demand for optical instruments having greater capability for more precise measurements of constituent content.
SUMMARY OF THE INVENTION
The instrument of the present invention, which is designed for use both in colorimetry and in constituent analysis applications, improves upon the above prior art optical analyzers by providing a novel optical system which achieves greater accuracy at high speed and permits analysis of darker samples than was possible with the prior art high speed systems. In the instrument of the invention, a concave holographic diffraction grating oscillated at high speed is utilized to provide a rapid scanning of the monochromatic light produced at varying wavelengths by the grating. In a concave holographic grating, the lines of the grating are formed by a holographic technique. Concave holographic gratings are presently available on the market and are marketed by J.-Y Diffraction Gratings, Inc. of Metuchen, New Jersey. The use of a concave grating is preferable to plane grating systems because it involves the use of a single optical component as opposed to three or more optical components required in the plane grating systems. As a result, the alignment in calibration procedures are simplifed and the cost of precision mechanical mounts are reduced. The use of a concave holographic grating makes possible the design of a system with low F numbers, for example as low as F/1 in some cases. High performance plane grating systems are usually limited F/4 and higher. The lower optical F numbers makes it possible to pass a greater amount of light energy through the optical system thereby making it possible for the present invention to analyze darker samples than were heretofore possible by prior optical analyzers. In addition, holographic gratings are free of ghosts and have a lower stray light level in comparison to rule gratings. Another advantage of the holographic grating used in the system of the present invention is that it can be made with a very high groove density which enables high resolution while maintaining high light energy throughput. Yet another advantage of the holographic grating is that it is corrected for astigmatic aberration and spherical and coma aberration are also reduced.
The holographic grating in this invention is made to oscillate at very high speed by means of a novel cam drive structure. The cam drive employes two identically shaped conjugate cams to provide positive drive of the grating in both directions. Each cam has a shape selected to make the grating output vary linearly with the angular position of the grating. The cams are also shaped so that different gratings can be used with the same cam drive for different wavelength ranges.
Use of a concave holographic grating permits the grating to disperse light radiation directed at it through an entrance slit into spectral components which are focused along a circle drawn through the entrance slit and the grating. The circle along which these spectral components are in focus is known as a Rowland circle. The exit slit is positioned such that each respective spectral component dispersed by the grating is optimized for best focus and minimum aberrations at the exit slit as the grating is oscillated to scan the wavelength range.
Because the holographic grating is oscillated at very high speed, a rapid scan technique is possible enabling the present invention to eliminate noise by averaging over a large number of cycles. More specifically, in the system of the present invention, the grating is oscillated at about 300 cycles per minute which, at two scans per cycle, provides 10 scans per second. At the end of each scan, a dark period is provided in order to permit drift correction. The dark period is provided by a filter wheel which has two dark segments arranged 180 degrees apart. The wheel is synchronized with the cam drive of the grating so that each respective dark segment corresponds to the grating orientation at one of its extreme positions in the oscillation cycle. The output can be measured by a photodetector during the dark periods to provide the necessary drift correction.
Another feature of the present invention involves the use of a polarizer at the entrance slit to polarize the light passing through the entrance slit irradiating the grating. The polarizer can be rotated to 90 degrees so that the axis of polarization can be varied.
The present invention further provides a novel technique for modifying the shape and size of the light source to meet the optimum requirements of the system. Present optical devices requiring white light sources for producing wide band radiation generally utilize an incandescent bulb typically including a tungsten filament. The shape and size of the filaments contained in commercially available bulbs are limited and are usually inadequate to satisfy the optimum demands of the optical systems. By providing a reflector positioned with respect to the light source to form a real image of the filament on top of or below the actual filament, the length of the filament can be effectively doubled so that an image of the "lengthened" filament source will completely fill the entrance slit with light. In another embodiment of the present invention, the reflector is positioned so that the filament is imaged next to itself to produce a source of light shaped as a square to approximate a circular light source.
The aforementioned optical modification to lengthen the filament permits optimization of the aspect ratio of the slit optics in the present invention. Since the ratio of the height of the entrace slit to its width in typically about 5.5, the abovedescribed optical modification permits the ratio of the filament height-to-width to approach the same 5.5 relationship and thereby completely fill the slit with source light. The alternative optical modification, producing an approximate circular light source, provides the ideal light source shape for projection of white light on the sample.
Both of the techniques for modifying the shape of the light source are achieved by a single manufactured structure in which the reflector it tiltable on a vertical axis passing through the reflector and is rotatable about an axis colinear with the optic axis of the source optics. By correctly adjusting the tilt of the reflector about the vertical axis and the rotational position of the reflector about the optic axis, the image of the filament can be positioned either to double the effective length of the filament or to widen it into a square.
Yet another improvement in the present invention involves an unique arrangement in one embodiment of optical lenses utilizing a cylindrical lens at the entrance slit for imaging the height of a spherical lens through which the light passes on the grating. This arrangement assures that the vertical dimension of the source illumination on the grating corresponds to the height of the grating. A second cylindrical lens is provided at the exit slit for virtually imaging the width of the exit slit back on the grating. Since the width of the exit slit imaged back on the grating and the height of the grating now remain constant regardless of the oscillation of the grating, the grating will project a monochromatic light image on the sample which is fixed in shape and size regardless of the oscillation of the grating.
The projection of the constant size monochromatic light image is further accomplished in the above described embodiment by means of additional lenses and by providing a variable aperture iris at a point where a real image of said monochromatic light image is projected. By changing the size of the iris aperture, the amount and size of the illumination projected on the sample can then be controlled.
Photodetectors are provided in the above described embodiment of the present invention to detect light radiation being either transmitted through or reflected by the sample according to the preferred application. Alternatively, the present invention provides for modification of the output detection by including fiber optics for effectively collecting light transmitted or reflected by the sample. The output of the fiber optics is then focused onto a photodetector for sample spectral analysis.
A further improvement of the present invention is an alternative optical arrangement utilizing the approximate circular light source described earlier to project white rather than monochromatic light on the sample. In this embodiment, the sample is located at the input of the optical system and light reflected by or, alternatively, transmitted through the sample is collected by a plurality of optical fibers arranged, for example, in a circular array. The other end of this fiber optics array is arranged linearly whereby the ends of the fibers form an entrance slit. Light is effectively transmitted through the fibers by internal reflection to completely fill the entrance slit so formed. The optical parameters of this fiber optics array are chosen such that each of the fibers accepts a cone of light reflected by or transmitted through the sample which is equal in angle to the acceptance cone of the grating. The light exiting from the linearly arranged end of the fibers will, therefore, project the light on the oscillating grating at an angle which will permit the light to completely fill the vertical dimension of the grating with all the light accepted and transmitted by fiber optics array. This improved design permits optimum utilization by the grating monochrometer of the light intensity transmitted through or reflected by the sample. The grating in this embodiment is also oscillated at very high speed as described earlier and provides spectral dispersion of the light at an exit slit. The spectral light passing through the exit slit is then sensed by a photodetector for spectral analysis of the sample.
Further objects and advantages of the present invention will become apparent by reference to the following detailed description of the preferred embodiments considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a preferred embodiment of the present invention utilizing an oscillating holographic grating wherein monochromatic radiation reflected by the sample is detected for spectral analysis;
FIG. 2 is a schematic diagram illustrating the light source optics of FIG. 1;
FIG. 3 is a sectional view illustrating the mounting system for a portion of light source optics of the system;
FIG. 4 is a diagrammatic illustration of a modification of FIG. 1 wherein monochromatic radiation transmitted through the sample is detected for spectral analysis;
FIG. 5 is a schematic diagram illustrating yet another modification of FIG. 1 wherein monochromatic radiation reflected by the sample is collected by fiber optics and transmitted to a photodetector;
FIG. 6 is a scehmatic diagram illustrating a similar modification as in FIG. 5 for collecting the radiation transmitted through the sample;
FIG. 7 is an illustration of the segmented filter wheel utilized in the system;
FIG. 8 is a perspective view of a second preferred embodiment of the present invention utilizing an oscillating holographic grating wherein white illumination reflected from a sample is collected by fiber optics and transmitted to the grating for dispersion and detection for spectral analysis;
FIG. 9 is a schematic diagram illustrating the light source input optics of FIG. 8;
FIG. 10 is a diagrammatic illustration of a modification of FIG. 8 wherein the fiber optics collects the illumination which is transmitted through the sample;
FIG. 11 is a schematic drawing of a plan view of a portion of FIG. 8 illustrating the light source optics and the fibers optics utilized in this second preferred embodiment;
FIG. 12 is a perspective view illustrating the cam drive structure utilized in the present invention to oscillate the holographic grating at very high speed; and
FIGS. 13 and 14 are schematic representations of two different positions of the cams and cam followers during the oscillation cycle of the grating.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the schematic illustration of FIG. 1, the spacings of some of the components of the system has been exaggerated to facilitate illustration. As shown in FIG. 1, a tungsten filament light bulb source 1 emits wide band white light. The light from the tungsten filament is collected by a spherical lens 2 and is imaged on an entrance slit 4. A cylindrical lens 3 assures proper filling illumination of the concave holographic diffraction grating of the system designated by reference number 5. The lens 3, while shown spaced from the slit 4, will actually be positioned immediately adjacent to the slit 4.
A polarizer 3b for linearly polarizing the light may be provided in the light path between the filter 3a and the cylindrical lens 3. The polarizer may be rotated about the optical axis through 90 degrees so that the axis of polarization can be varied. The polarizer, which serves to make possible irradiation of the sample with polarized light, is useful in constituent analysis applications in which the axis of polarization will be selected experimentally to give the most accurate determinations of the constituents of the sample.
The novel source optics is more clearly illustrated in FIG. 2, wherein the reflector 6 is positioned with respect to the filament 1a of the tungsten filament light source 1 so that an image 1b of the filament 1a is formed immediately above the filament 1a, thereby effectively doubling the length of the tungsten filament. This optical modification is important in the present optical system since commercially available tungsten filament lamps do not have filaments with a height-to-width ratio corresponding to the height-to-width ratio of the entrance slits, such as slit 4, commonly used in monochrometer optical systems. By effectively doubling the length of the filament 1a by means of reflector 6, a linear filament light source is provided which will approximately correspond to the aspect ratio of the entrance slit 4. The spherical lens 2 forms an image of the filament and the adjacent filament image on the entrance slit 4 to completely fill the entrance slit 4 with illumination. The axis of curvature of the cylindrical lens 3 is horizontal and this lens serves to focus the vertical dimension of the spherical lens 2 on the grating 5 so as to make the vertical dimension of the illumination on the grating correspond to the height of the grating. An infrared filter 3a filtering out infrared light is provided to reduce stray source light and unnecessary heat energy produced by the source. Altneratively, a filter may be utilized in place of infrared filter 3a to pass infrared radiation when the grating and other components of the optical system are chosen for infrared analysis of the sample.
The sectional view in FIG. 3 illustrates the mechanism for mounting the reflector 6 in order to adjust it to the position to form the image of the filament in the desired position. As shown in FIG. 3, the light source 1 is mounted in a tube 41 in which the lens 2 is also mounted with its optic axis in alignment with the center line of the tube 41. The lens 2 is actually mounted in a sleeve 43 which is axially slidable in the tube 41 to permit adjustment of the axial position of the lens 2 for the purposes of properly adjusting the focus of the lens 2. The reflector 6 is mounted in a support member 45 which, in turn, is pivotally mounted in a round, hollow support member 47, the support member 45 being pivotal with respect to the support member 47 on an axle 49 positioned so that the pivot axis is perpendicular with the optical axis of the lens 2 and is in alignment with the reflector surface at the middle thereof. A set screw 51 is threaded through the back wall of the support member 47 to engage the back of the support member 45 positioned spaced from the axle 49. A compression spring 53 is positioned between the back of the support member 45 and the back wall of the support member 47 and engages the back wall of the member 45 spaced from the axle 49 on the opposite side from the set screw 51. As the set screw 51 is advanced, it will pivot the support member 45 and, therefore, the reflector 6 on the axle 49 against the force of the spring 53. Thus, by adjusting the set screw 51, the angular position of the reflector 6 with respect to the support member 47 can be adjusted. The support member 47 defines a cylindrical surface 55 which engages the outer cylindrical surface of the tube 41 so as to make the support member 47 rotatable with respect to the tube 41 about the optical axis of the lens 2.
In order to employ the mechanism shown in FIG. 3 to position the image of the filament in alignment with the filament itself as illustrated in FIG. 2, the angular position of the reflector 6 with respect to the support member 47 is adjusted by means of the set screw. This adjustment positions the image 1b of the filament 1a at a selected distance from the filament 1a, the distance changing as the reflector is pivoted on the axle 49. When the reflector 6 has been pivoted to space the image 1b from the filament 1a, rotation of the support member 47 about the tube 41 will rotate the image 1b about the image 1a. Thus, by combined adjustment of the angular position of the reflector 6 with respect to the support member 47 and the angular position of the support member 47 with respect to the tube 41 and the source 1, the filament image 1b can be brought into the position illustrated in FIG. 2 where it is aligned with the filament 1a and spaced therefrom by an amount to be a continuation of the filament 1a. The same mechanism shown in FIG. 3 is used in another embodiment of the invention in which the image of the filament is positioned to make the light source in the form of a square as is described in more detail below.
Grating 5 is a concave holographic grating of the type discussed earlier which is made to oscillate at very high speed in both directions, as generally indicated by the arrow in FIG. 1, by a cam drive structure which will be further discussed below with reference to FIG. 11. The oscillation of the grating 5 is synchronized with the rotation of filter wheel 7 about its axis, the synchronization being schematically represented in FIG. 1 by the dashed line from grating 5 to filter wheel 7.
Holographic grating 5 disperses the white illumination imaged on it through the entrance slit 4 into spectral components which are focused at the exit slit. Alternatively, a holographic grating may be used which disperses infrared radiation when infrared analysis of the sample is contemplated.
Cylindrical lens 9, the axis of curvature of which is vertical as distinguished from cylindrical lens 3 wherein the curvature axis is horizontal, virtually images the width of exit slit 8 back on the grating 5. Because the width of exit slit 8 imaged on the grating 5 and the height of the grating are constant regardless of the oscillation of the grating, constant size illumination of a sample with the light dispersed by the grating can be efficiently achieved even though the grating is oscillating. The oscillation of grating 5 will vary the wavelength but not the size or shape of the illumination on the sample.
The projection of the constant size monochromatic illumination is accomplished by means of the additional lenses and mirrors illustrated in FIG. 1 comprising the unique output optics of this preferred embodiment. Since cylindrical lens 9 has provided an image of the width of exit slit 8 on the grating 5, an image object is formed at the grating comprising a composit of the grating height and the virtual lamp of the exit slit width. After the beam of light passes through filter wheel 7, it is reflected by mirror 10 to a spherical lens 11. Spherical lens 11 forms a real image of the composit of the slit width and grating height at a variable aperture iris 12. Because the width of the slit is constant and the height of the grating is constant, this real image formed at the iris aperture 12 will be of constant size. If the cylindrical lens 9 were not present, the image formed at the iris aperture 12 would vary in width as the grating changes its angular position. By changing the size of the opening (F-stop) of the iris aperture 12, the amount and size of illumination from the real image so produced at iris 12 for illuminating the sample 15 can be controlled. The illumination from the image formed at iris 12 is then reflected by mirror 13 to spherical lens 14, which takes the image that was formed at the iris 12 and focuses it on the sample 15 which has been positioned on supporting plate 16. Because the image at the iris 12 is of constant size, the image on the sample will be of constant size. The light diffusively reflected from sample 15 is then sensed by photodetectors 17 for spectral analysis.
FIG. 4 illustrates a modification of the preferred embodiment in FIG. 1 wherein sample 15 is positioned to permit the monochromatic illumination to be transmitted through the sample. The illumination from the iris 12 is reflected by mirror 13 and focused by spherical lens 14 through sample 15 on a diffusive white reflector 18. The radiation transmitted by sample 15 is reflected by the white reflector 18 and sensed by photodetectors 17 for subsequent spectral analysis of the sample. Alternatively, the sample 15 may be positioned adjacent to the variable aperture iris 12 in FIG. 1 so that illumination passing through iris aperture 12 and transmitted through the sample 15 will be subsequently sensed by photodetectors 17.
The filter wheel 7 shown in FIG. 1 is driven by a motor so as to be synchronized with the oscillation of grating 5. Referring to FIG. 7, a plan view of filter wheel 7 is there illustrated. The filter wheel 7 has two dark segments 7a arranged 180 degrees apart and two circular segments 7b running between the two dark segments. Each circular segment is a narrow bandwidth filter having linearly changing wavelengh transmission bands such that the portion of each segment closer to the top of the filter wheel 7 will pass higher wavelengths than that portion closer to the bottom of the filter wheel. Filter wheel 7 is so constructed that one side of the filter is a mirror image of the other side about a line passing through the middle of the opaque or dark segments 7a.
For each complete oscillation of the grating 5, the filter wheel 7 will revolve 360 degrees about its axis and is arranged to position each respective dark segment 7a to interrupt or block the light passing through the exit slit 8 at each corresponding extreme position of the grating in its oscillation cycle. The output of the optical system can be measured by photodetectors 17 during these dark periods to provide the necessary drift correction. The filter wheel 7, in addition to limiting stray light, also eliminates second order light which will be half the wavelength of the primary light. For example, if light is being transmitted through the exit slit at 800 nanometers in wavelength, there will also be some light transmitted at 400 nanometers. The filter wheel 7 serves to eliminate this light as well.
FIGS. 5 and 6 illustrate yet further modifications of the optics associated with the sample in FIGS. 1 and 4, respectively. In FIG. 5, for example, instead of positioning the photodetectors 17 to directly receive light reflected by sample 15 as in FIG. 1, fiber optic bundles 20 are disposed to collect and transmit this reflected light to the photodetector 17 by means of internal reflection. The fiber optic bundles are arranged so that the endfaces 20a of each fiber bundle are positioned to form circular distribution facing the sample on a conical locus so as to collect the illumination being reflected by sample 15. The endfaces 20a are mounted on a conical support member 55, which may be made transparent to reduce the amount of stray light reflected by the support member. As in FIG. 1, mirror 13 reflects the illumination of the image formed at iris 12 which is then focused by lens 14 on sample 15. The illumination reflected by the sample is collected by the fiber bundles at their endfaces 20a and transmitted to the opposite endfaces 20b of the fiber bundles. Endfaces 20b are arranged in a plane to form a circle. The light emitted from endfaces 20b is then focused by lens 19 on photodetector 17 for spectral analysis. The photodetector will be substantially smaller than the circle formed by the endfaces 20b of the fiber bundles. The lens 19 focuses all of the light emitted from the end surfaces 20b into a spot on the photodetector corresponding in size to the size of the photodetector.
In FIG. 6, a similar modification is shown with respect to the photodetection of radiation transmitted through the sample 15 previously illustrated in FIG. 4. Monochromatic light is focused by lens 14 through the sample 15 onto white diffusive reflector 18. The light reflected by reflector 18 enters endfaces 20a of the fiber optic bundles 20, again arranged in a conical circular distribution in support member 55, and is transmitted by the bundles 20 to the opposite endfaces for projection on and detection by a photodetector as explained in connection with FIG. 5. Alternatively, the sample 15 may be positioned adjacent variable aperture iris 12 in FIG. 1 so that illumination passing through iris aperture 12 and transmitted through the sample 15 will be subsequently sensed by photodetector 17 after being collected by and transmitted through fiber optics 20.
A perspective view of a second preferred embodiment of the present invention is shown in FIG. 8. Wide band white light illumination from a tungsten filament light bulb source 21 is projected by the optics shown to form a spot of illumination on sample 28. The novel source optics is more clearly illustrated in FIG. 9 wherein the tungsten filament light source 21 is shown having a filament 21a. Since in this embodiment, the sample is to be illuminated by white light rather than the monochromatic illumination utilized in FIG. 1, the ideal shape of the illumination to be projected on the sample should be a spot or circle of light. Since tungsten filaments are not commonly formed in circular shapes, the present embodiment contemplates optically modifying the tungsten filament light source in order to achieve this goal. To this end, a reflector 22 is positioned as shown in FIG. 8 to form an image 21b of filament 21a along side of itself. The light source so formed is shaped as a square, which more clearly approximates the ideal shape of a circle than the linear filament. The square filament source is imaged by lens 24 on lens 27. The latter lens 27 in turn will project an image of the illumination at iris 25 on the sample. The variable aperture iris 25 is positioned adjacent to lens 24 to control the size of, and, therefore, the amount of illumination being projected on the sample. Mirror 26 is necessary to "fold" the light illumination from the source upwards toward the sample. An infrared filter 26a is provided to reduce stray source light and unnecessary heat energy produced by the source. Alternatively, a filter may be utilized in place of infrared filter 26a to pass infrared radiation when the grating and other components of the optical system are chosen for infrared analysis of the sample.
An advantage of using the two lenses 24 and 27 as described above is that this arrangement produces a nearly round spot of light on the sample, which is variable in size. Because the shape of the light source by the operation of the reflector 22 producing an image of the filament next to itself has made it approximately square in shape, the illumination passing through the lens 24 will substantially fill the lens 24. As a result, when the lens 27 focuses an image of the iris which is adjacent to lens 24 on the sample 28, it produces an almost uniform round circle of light on the sample.
To achieve the positioning of the image 21b so that the filament 21a and the image 21b form the shape of a square, the same mechanism illustrated in FIG. 3 is used. Thus, a single manufactured part serves both in the embodiment in which the sample is irradiated with wide band light used in the embodiments in which the sample is irradiated with narrow band light after it has been dispersed by the grating.
The entire input optics is schematically shown in FIG. 11, which is a sectional view in elevation of a portion of FIG. 7. The circle or spot of light projected on sample 28, which as been positioned on a supporting plate 34, by means of the optics described above, is diffusively reflected by sample 28. The reflected illumination is collected by the endfaces of a fiber optics array 29 which is comprised of a plurality of individual fiber bundles arranged at one end on a conical locus to receive reflected illumination from the sample. The ends of the fiber bundles are mounted in a conical member 57 which may be made transparent to reduce the amount of stray light reflected by the support member. At the other end, the ends of the fiber bundles of the fiber optics array 29 are arranged linearly to form an entrance slit 30. Light reflected by sample 28 is therefore effectively transmitted through the fibers by internal reflection to completely fill the entrance slit 30. The optical parameters of the fiber optic array 29 are chosen such that each fiber accepts a cone of light reflected by the sample 28 which is equal in angle to the acceptance cone of the grating 31.
Referring again to FIG. 8, the light exiting from the linear endface 30 formed by the fiber optics array 29 will, therefore, project the light transmitted by the array 29 on the grating 31 at an angle which will permit the light to completely fill the grating 31 with all the light illumination accepted and transmitted by the fiber optics array 29. This improved design utilizing the fiber optics array 29 permits optimum utilization by the grating 31 of the light intensity reflected by the sample 28 and transmitted through the fiber optics 29.
The grating 31 in this embodiment is also oscillated at very high speed as described earlier in connection with the embodiment of FIG. 1 and provides rapid scanning of the spectral light dispersed at an exit slit 32. The monochromatic light passing through exit slit 32 is sensed by photodetector 33 for spectral analysis of the sample. Alternatively, a holographic grating may be used which disperses infrared radiation when infrared analysis of the sample is contemplated.
A filter wheel 7 of the identical structure as filter wheel 7 of FIG. 7 is positioned immediately after the exit slit 32 in FIG. 8. Filter wheel 7 is synchronized with the oscillation of grating 31 for the identical purpose as was filter wheel 7 in FIG. 1.
The embodiment of FIG. 8 can be further modified to detect radiation transmitted by the sample as shown in FIG. 10. The sample 28 is so arranged that the spot of source light transmitted through sample 28 is reflected by a diffusive white reflector 34a. The reflected light is then collected by the endface of the fiber optic array 29, as described in connection with FIG. 8, and is transmitted through individual fibers of array 29 by internal reflection to their opposite ends forming entrance slit 30. The operation is then exactly the same as described in connection with FIG. 8 above.
FIG. 12 schematically illustrates the cam drive structure for oscillating grating 5 of FIG. 1 or grating 31 of FIG. 7 at very high speed. The cam drive employs two identically heart-shaped conjugate cams 35 and 36 to provide positive drive of the grating in both directions as shown by the arrow. The shape of the cams has been selected to make the grating output vary linearly with the angular position of the grating and to, furthermore, permit different gratings to be used with the same cam drive for different applications. Each conjugate cam has a cam follower associated therewith depicted in FIG. 12 as 35a and 36a. The conjugate cams 35 and 36 are driven by a high speed motor 37 through gears 38 and 39. Cam followers 35a and 36a track the lateral surfaces of their respective heart-shaped cams 35 and 36 as the latter are rotated about their axis by pin 40 which is driven by motor 37 through gears 38 and 39. As the cam followers track the conjugate cams, they cause the grating to oscillate at very high speed.
FIGS. 13 and 14 are schematic representations of the two extreme positions of the grating in its oscillation cycle and the respective positions of the conjugate cams and their cam followers. In FIG. 13, for example, the grating is shown at one extreme position in its oscillation cycle corresponding to cam follower 36a being at the maximum throw of cam 36 while cam follower 35a is at the minimum throw of cam 35. In FIG. 14, the opposite extreme position of the grating is shown wherein the opposite relationship exists with respect to the cams and their followers. In FIG. 14, cam follower 35a is now on the maximum throw of cam 35 while cam follower 36a is on the minimum throw of cam 36.
With the above described cam system, each acceleration and deceleration of the grating during its oscillation is effected by the action of one of the cam surfaces pushing on a cam follower and no spring is required to maintain either of the cam followers in engagement with the corresponding cam surface. As a result, the cam drive enables the holographic grating to be oscillated at a very high speed, for example 300 cycles per minute, to thereby permit the grating to rapidly scan the exit slit ten times per second. This rapid scanning makes it possible for the present invention to eliminate noise by averaging over a large number of oscillation cycles.
The rotation of the filter wheel 7 in the embodiments of FIGS. 1 and 8 is, of course, synchronized with the cam drive of FIG. 12 as described earlier so that each revolution of the filter wheel 7 will correspond to one complete oscillation cycle of the grating. Further as described above, filter wheel 7 is initially oriented so that one dark segment 7a of the filter wheel will block the light path when the grating and the cam drive are in the position shown by FIG. 13. The opposite dark segment 7a of filter wheel 7 will likewise block the light path when the grating and the cam drive are in the position shown by FIG. 14. The exact manner in which the filter wheel rotation is synchronized with the grating oscillation is not shown in the drawings but can be easily implemented by those skilled in the art by means of, for example, additional gears associated with motor 37 and gears 38 and 39 of FIG. 12 for driving the filter wheel.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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An improved optical system is disclosed for rapid, accurate spectral analysis of the reflectivity or transmissivity of samples. A concave holographic diffraction grating oscillated at high speed is utilized to provide a rapid scanning of monochromatic light through a spectrum of wavelengths. The grating is positively driven at very high speed by a unique cam drive structure comprising identically shaped conjugate cams. The rapid scan by the grating enables the reduction of noise error by averaging over a large number of cycles. It also reduces the measurement time and thus prevents sample heating by excessive exposure to light energy. A filter wheel having dark segments for drift correction is rotated in the optical path and is synchronous with the grating. Source optics is employed to optimally shape the light source for particular applications. The system optics further includes a unique arrangement of lenses, including cylindrical lenses, to obtain the best light source shape which results in maximum light throughput. Fiber optics are also employed and arranged to meet the optimum requirements of the system for light collection and transmission through portions of the optical system.
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TECHNICAL FIELD
[0001] The present invention relates to a deadlock avoidance method and a deadlock avoidance mechanism.
BACKGROUND ART
[0002] In recent years, in order to improve flexibility of processing, there has increased an LSI (Large Scale Integration) in which a dedicated coprocessor is connected to a built-in processor core to perform signal processing.
[0003] In the LSI in which the coprocessor core and the processor are connected to each other, a coprocessor 20 and a data memory 30 can be directly connected to each other as shown in FIG. 5 . The coprocessor 20 directly performs read and write of data with respect to the data memory 30 . As a result of this, data traffic of a processor core 10 is reduced, and performance can be improved.
[0004] For example, Patent Literature 1 discloses a configuration in which data is directly transferred between a coprocessor and a data memory.
[0005] For example, the following methods are included in techniques to generate an address required for data exchange between the coprocessor and the data memory etc.
[0006] (1-1) A method in which a data transfer circuit in the coprocessor automatically generates the address
[0007] (1-2) A method for directly embedding an address value in an instruction (hereinafter referred to as a coprocessor instruction) issued to the coprocessor
[0008] (1-3) A method for embedding an update parameter of the address value in the coprocessor instruction
[0009] (1-4) A method for appropriately supplying the address from a processor core
[0010] Among the above-described methods, “(1-1) The method in which the data transfer circuit in the coprocessor automatically generates the address” has a high processing efficiency, and has a high efficiency of a control program. Hereinafter, a coprocessor in an LSI in which the method is employed will be described with reference to FIG. 6 . A data transfer circuit 23 in the coprocessor automatically generates an address using a data transfer parameter 231 . The data transfer circuit 23 reads data from the data memory 30 using the generated address. The data transfer circuit 23 writes the read data in an arithmetic unit 22 through a data input FIFO (First In First Out) 25 . The arithmetic unit 22 performs arithmetic operation using the input data, and writes an arithmetic result in a data output FIFO 26 and the data transfer circuit 23 .
[0011] When an address is automatically generated in the data transfer circuit 23 , a parameter for address generation (a data transfer parameter) is set to the data transfer circuit 23 , and after that, a series of coprocessor instructions are issued. The data transfer circuit 23 generates the address using the data transfer parameter 231 in synchronization with the issue of the coprocessor instructions. After address generation, the data transfer circuit 23 performs data write or data read in or from the data memory 30 . Each configuration of the LSI is implemented so that the above-mentioned operation is performed.
[0012] When the data transfer circuit 23 in the coprocessor 20 generates the address, a plurality of data transfer parameter settings may be required for the data transfer circuit 23 depending on complexity of the address to be generated. When the address to be generated does not vary, and it is simple, setting of the data transfer parameter may just be performed only once. However, for example, when an address is irregularly changed in the middle of execution of the coprocessor instruction, resetting of the data transfer parameter is required during execution of the coprocessor instruction.
[0013] For example, the following methods are included in methods for resetting a data transfer parameter.
[0014] (2-1) A method for repeatedly execute each processing included in a coprocessor instruction, repeatedly halting processing in a timing required for address change, and setting a data transfer parameter.
[0015] (2-2) A method for generating interrupt to a coprocessor in a timing of changing an address, and setting a data transfer parameter in interrupt processing
[0016] The above-mentioned method of (2-1) will be described with reference to FIG. 7 . As shown in FIG. 7 , a coprocessor repeatedly executes a coprocessor instruction (loop processing in S 22 ). In the timing when an address is changed, a data transfer parameter is set from outside (S 21 ). When this method is employed, it is necessary to generate a control program in consideration of the timing of address change. Therefore, there is such a problem that when the address is irregularly changed in the middle of execution of the coprocessor instruction, the control program becomes complicated.
[0017] Subsequently, the method of (2-2) will be described with reference to FIGS. 8 and 9 . First, there will be described general operation in a case where interrupt processing is executed to a coprocessor with reference to FIG. 8 .
[0018] In the case where interrupt processing to the coprocessor is performed during execution of a coprocessor instruction, when the interrupt processing is executed before the end of the coprocessor instruction, problems, such as resource mismatch inside the coprocessor, may occur. Therefore, interrupt processing is suspended until the coprocessor instruction is ended as shown in FIG. 8 .
[0019] For example, Patent Literature 2 discloses a technology in which when external interrupt is generated during processing of a vector instruction, processing of the external interrupt is suspended until the processing of the vector instruction is ended. As a result of this, an arithmetic result of the vector instruction is prevented from being an illegal value.
[0020] Subsequently, the method of (2-2) will be described with reference to FIG. 9 . As shown in FIG. 9 , interrupt is generated at a timing when a parameter for address generation needs to be reset (S 43 ). As a result of this, a control program of an LSI can be simplified.
[0021] However, this method causes such a problem that deadlock may occur. The problem will be described with reference to FIG. 10 . As described with reference to FIG. 8 , in order to avoid resource mismatch, interrupt processing is generally executed after the program waits until the end of the coprocessor instruction. Therefore, interrupt processing is not executed until the end of the coprocessor instruction (S 51 ). Meanwhile, since interrupt processing is not executed, parameter setting of a data transfer circuit is not executed (S 52 ). Since the parameter setting is not executed, data acquisition (access to a data memory) by the coprocessor instruction being executed cannot be executed (S 53 ). Therefore, the coprocessor instruction is not ended (S 54 ). As described above, a deadlock state occurs.
[0022] Patent Literature 3 discloses a technology to eliminate deadlock due to the program continuing to wait until data is held in a buffer in performing stream data. In the technology, when timeout occurs, deadlock is avoided by inserting dummy data in an FIFO buffer that holds the stream data. Namely, a configuration is disclosed in which processing is forcibly executed for each certain time.
CITATION LIST
Patent Literature
[0000]
[Patent Literature 1]
[0024] Published Japanese Translation of PCT International Publication for Patent Application, No.2002-503370
[Patent Literature 2]
[0026] Japanese Unexamined Patent Application Publication No. 2005-092467
[Patent Literature 3]
[0028] Japanese Unexamined Patent Application Publication No. 2009-271610
SUMMARY OF INVENTION
Technical Problem
[0029] In the technology of Patent Literature 3, deadlock is avoided by continuing processing after occurrence of timeout, i.e., after a certain latency time. Since the certain latency time occurs, processing cannot be quickly executed by the technology of Patent Literature 3.
[0030] Consequently, the present invention is mainly directed to situations as in the above-mentioned (1-1) and (2-2). Namely, the present invention is directed to a situation where processing to the coprocessor is performed by interrupt processing during execution of the coprocessor instruction. As mentioned above, interrupt processing is not executed until the coprocessor instruction is ended in order to avoid resource mismatch in the coprocessor. Therefore, in a general LSI configuration, deadlock may occur in processing being performed to the coprocessor (the parameter for address generation being set in the above-mentioned example).
[0031] The present invention is made with respect to the above-described problem, and a main object thereof is to avoid deadlock in a processor system that performs processing to a coprocessor by interrupt processing during execution of a coprocessor instruction.
Solution to Problem
[0032] In a first exemplary aspect of the present invention, a deadlock avoidance method, wherein a cancellation request that requests cancellation of a coprocessor instruction being executed in a coprocessor is issued from a processor core, and in the coprocessor that has received the cancellation request, an execution state of the coprocessor instruction being executed is determined, the coprocessor instruction is canceled or suspended according to the determination, and the execution state of the coprocessor instruction is saved in the coprocessor instruction being suspended, after that, interrupt processing that performs processing to the coprocessor instruction is executed, and the saved execution state of the coprocessor instruction is restored after end of the processing.
[0033] In a second exemplary aspect of the present invention, a deadlock avoidance mechanism comprising a processor core and a coprocessor, wherein the processor core comprises: a processor core interrupt control circuit that issues a cancellation request that requests cancellation of a coprocessor instruction being executed in the coprocessor; and a program control circuit that starts interrupt processing that performs processing to the coprocessor after issuance of the cancellation request, and wherein the coprocessor comprises: a coprocessor arithmetic control circuit that holds an execution state of the coprocessor instruction; and a coprocessor interrupt control circuit that cancels or suspends the coprocessor instruction based on information that the coprocessor arithmetic control circuit holds in receiving the cancellation request, saves the execution state of the coprocessor instruction when the coprocessor instruction is suspended, and restores the saved execution state of the coprocessor instruction after end of the interrupt processing.
Advantageous Effects of Invention
[0034] According to the present invention, can be provided a deadlock avoidance method and a deadlock avoidance mechanism that can avoid deadlock in a processor system that performs processing to a coprocessor by interrupt processing during execution of a coprocessor instruction.
BRIEF DESCRIPTION OF DRAWINGS
[0035] [ FIG. 1 ] FIG. 1 is a block diagram showing a configuration of a deadlock avoidance mechanism pertaining to an embodiment 1.
[0036] [ FIG. 2 ] FIG. 2 is a block diagram showing a configuration of a coprocessor interrupt control circuit 24 pertaining to the embodiment 1.
[0037] [ FIG. 3 ] FIG. 3 is a flow chart showing processing of the deadlock avoidance mechanism pertaining to the embodiment 1.
[0038] [ FIG. 4 ] FIG. 4 is a block diagram showing the configuration of the deadlock avoidance mechanism pertaining to the embodiment 1.
[0039] [ FIG. 5 ] FIG. 5 is a block diagram showing a general configuration of LSI.
[0040] [ FIG. 6 ] FIG. 6 is a block diagram showing a general configuration of a coprocessor.
[0041] [ FIG. 7 ] FIG. 7 is a flow chart showing a flow of processing in a case where setting of data transfer parameters is all performed by main processing.
[0042] [ FIG. 8 ] FIG. 8 is a flow chart which showing operation in a case of performing interrupt processing to the coprocessor.
[0043] [ FIG. 9 ] FIG. 9 is a flow chart showing a flow of processing in a case where setting of data transfer parameters is performed by interrupt processing.
[0044] [ FIG. 10 ] FIG. 10 is a conceptual diagram showing occurrence of deadlock.
DESCRIPTION OF EMBODIMENTS
Embodiment 1
[0045] Hereafter, an embodiment of the present invention will be described with reference to drawings. A deadlock avoidance mechanism 1 pertaining to the embodiment includes: a processor core 10 , a coprocessor 20 ; and a data memory 30 . The deadlock avoidance mechanism 1 is incorporated in an LSI (Large Scale Integration) for signal processing that is used for cell-phone terminals or AV (audio-visual) equipment, etc.
[0046] The processor core 10 includes: a program control circuit 11 ; and a processor core interrupt control circuit 12 .
[0047] The program control circuit 11 issues a coprocessor instruction or interrupt processing to the coprocessor 20 as a coprocessor arithmetic control signal. When there is no supply of a wait signal from a coprocessor arithmetic control circuit 21 , the program control circuit 11 can perform the issue. The coprocessor instruction is an instruction that generally has a plurality of cycles. The interrupt processing is processing to reset a data transfer parameter 231 in the embodiment.
[0048] The program control circuit 11 holds a status indicating whether or not the coprocessor instruction (instruction to the coprocessor 20 ) is being executed. It is to be noted that the program control circuit 11 can hold not only the above-described two types of statuses but various statuses. The program control circuit 11 notifies the processor core interrupt control circuit 12 of the held status according to a query from the processor core interrupt control circuit 12 .
[0049] When notified of start of interrupt processing by the processor core interrupt control circuit 12 , the program control circuit 11 notifies the coprocessor arithmetic control circuit 21 of a processing content of the interrupt processing for resetting the data transfer parameter 231 .
[0050] When the data transfer parameter 231 needs to be reset, the processor core interrupt control circuit 12 queries the program control circuit 11 of a current status, i.e., whether or not the coprocessor instruction is being executed. The data transfer parameter 231 is reset, for example, in an interrupt signal being supplied from a data transfer circuit 23 . Details of the data transfer parameter 231 will be mentioned later. When the coprocessor instruction is being executed, the processor core interrupt control circuit 12 supplies a processing cancellation request signal to the coprocessor interrupt control circuit 24 .
[0051] The processor core interrupt control circuit 12 receives a processing cancellation determination signal from the coprocessor interrupt control circuit 24 as a response of a processing cancellation request signal. The processing cancellation determination signal is a determination signal indicating whether the coprocessor instruction has been suspended or the coprocessor instruction has been canceled. The processor core interrupt control circuit 12 stores the received determination signal. The processor core interrupt control circuit 12 then notifies the program control circuit 11 of the start of the interrupt processing.
[0052] The processor core interrupt control circuit 12 performs resumption indication of the coprocessor instruction, or reissue of the coprocessor instruction, after interrupt processing is ended. When the stored determination signal is the signal related to suspension, the processor core interrupt control circuit 12 supplies a processing resumption request signal to the coprocessor interrupt control circuit 24 . When the stored determination signal is the signal related to cancellation, the processor core interrupt control circuit 12 reissues the canceled coprocessor instruction through the program control circuit 11 .
[0053] It is to be noted that the program control circuit 11 need not necessarily reissue the canceled coprocessor instruction, and may determine whether to reissue it according to the held status.
[0054] The coprocessor 20 includes: the coprocessor arithmetic control circuit 21 ; a coprocessor arithmetic unit 22 ; the data transfer circuit 23 ; and the coprocessor interrupt control circuit 24 .
[0055] The coprocessor arithmetic control circuit 21 supplies a wait signal to the program control circuit 11 , when the coprocessor instruction is being executed. The coprocessor arithmetic control circuit 21 makes the coprocessor arithmetic unit 22 execute processing of each cycle included in the coprocessor instruction.
[0056] Furthermore, when notified of interrupt processing, the coprocessor arithmetic control circuit 21 notifies the data transfer circuit 23 of the processing content of the interrupt processing, and makes it reset the data transfer parameter 231 . The coprocessor arithmetic control circuit 21 supplies the wait signal to the program control circuit 11 also during execution of the interrupt processing.
[0057] The coprocessor arithmetic control circuit 21 holds an execution situation as a status (hereinafter also described as a processing status) during execution of the coprocessor instruction. In the processing status, included is information, such as the number of steps currently being executed, whether or not data write has been performed in an external storage section (the data memory 30 or an arbitrary register (not shown)), and information of a pair of address information of the storage section to which data write has been performed and a written value.
[0058] The coprocessor arithmetic control circuit 21 supplies to the coprocessor interrupt control circuit 24 a processing status signal including information on the processing status according to a query from the coprocessor interrupt control circuit 24 .
[0059] When a processing suspension signal or a processing cancellation signal is input from the coprocessor interrupt control circuit 24 , the coprocessor arithmetic control circuit 21 ends the coprocessor instruction currently being executed. When receiving a processing resumption signal and a processing resumption status signal from the coprocessor interrupt control circuit 24 , the coprocessor arithmetic control circuit 21 resumes the coprocessor instruction from an execution situation according to the processing resumption status signal.
[0060] The coprocessor arithmetic unit 22 is the arithmetic unit that executes each cycle of the coprocessor instruction. The coprocessor arithmetic unit 22 performs read and write of data through the data transfer circuit 23 , when the data memory 30 needs to be accessed.
[0061] The data transfer circuit 23 performs access to the data memory 30 according to a request of the coprocessor arithmetic unit 22 . The data transfer circuit 23 generates an address that is required for access to the data memory 30 using the data transfer parameter 231 .
[0062] The data transfer parameter 231 is a parameter utilized in the address required for access to the data memory 30 being generated. Information, such as address initial value, the upper limit number of transfer, an address difference, is included in the data transfer parameter 231 .
[0063] The address initial value is information indicating an initial value in the data transfer circuit 23 accessing the data memory 30 . The upper limit number of transfer is the maximum number of transfer (read or write of data) to the data memory 30 . When data transfer is performed the maximum number of times, the data transfer parameter 231 needs to be reset. The address difference is a difference between a recently accessed address and an address to be accessed next.
[0064] When resetting of the data transfer parameter 231 needs to be performed, the data transfer circuit 23 supplies an interrupt signal to the processor core interrupt control circuit 12 .
[0065] The coprocessor interrupt control circuit 24 controls interrupt processing. There will be described details of a configuration and operation of the coprocessor interrupt control circuit 24 with reference to FIG. 2 .
[0066] The coprocessor interrupt control circuit 24 includes: a control circuit 241 ; a cancellation determination circuit 242 ; and a suspension state storing register 243 .
[0067] The control circuit 241 instructs start of cancellation determination to the cancellation determination circuit 242 , when a processing cancellation request signal is input. A processing cancellation determination signal is supplied to the control circuit 241 from the cancellation determination circuit 242 .
[0068] The control circuit 241 generates a control signal (a processing suspension signal or a processing cancellation signal) with reference to a value of the processing cancellation determination signal, and supplies the generated control signal to the coprocessor arithmetic control circuit 21 .
[0069] When the processing cancellation determination signal is the signal indicating suspension (the signal to determine that the coprocessor instruction currently being executed should be suspended), the control circuit 241 generates a processing suspension signal to instruct suspension of the coprocessor instruction being executed, and supplies the processing suspension signal to the coprocessor arithmetic control circuit 21 . In addition to this, the control circuit 241 writes in the suspension state storing register 243 each value (for example, a number of a cycle being executed, a temporary value of arithmetic operation, a value written in a register, and a writing destination) of the processing status signal input from the cancellation determination circuit 242 .
[0070] When the processing cancellation determination signal is the signal indicating cancellation (the signal to determine that the coprocessor instruction currently being executed can be canceled), the control circuit 241 generates a processing cancellation signal to instruct cancellation of the coprocessor instruction being executed, and supplies the processing cancellation signal to the coprocessor arithmetic control circuit 21 .
[0071] A processing resumption request signal is input to the control circuit 241 from the processor core interrupt control circuit 12 . According to this, the control circuit 241 supplies a processing resumption signal to the coprocessor arithmetic control circuit 21 . In addition to this, the control circuit 241 reads a value of the suspension state storing register 243 , and supplies the read value to the coprocessor arithmetic control circuit 21 as a status signal for resumption. As a result of this, the control circuit 241 restores an execution state of the coprocessor instruction.
[0072] The cancellation determination circuit 242 determines whether the coprocessor instruction currently being executed can be canceled, or should be suspended according to start indication of cancellation determination from the control circuit 241 . The cancellation determination circuit 242 performs the determination according to the processing status signal supplied from the coprocessor arithmetic control circuit 21 . As mentioned above, information, such as the number of steps currently being executed and whether or not data write has been performed to the storage section (the data memory 30 or an arbitrary register), is included in the processing status. The cancellation determination circuit 242 performs the determination, for example, according to whether or not data has been already written outside. When the value has been written in the storage section in an executed cycle, the cancellation determination circuit 242 determines that the coprocessor instruction currently being executed should be suspended. The cancellation determination circuit 242 supplies a determination result to the control circuit 241 and the processor core interrupt control circuit 22 as a processing cancellation determination signal. Furthermore, the cancellation determination circuit 242 supplies a processing status signal to the control circuit 241 .
[0073] The suspension state storing register 243 stores a parameter used in the suspended coprocessor instruction being resumed.
[0074] Subsequently, there will be described operation of the deadlock avoidance mechanism 1 pertaining to the embodiment with reference to FIGS. 1 and 3 . FIG. 3 is a flow chart showing a flow of processing from generation of an interrupt signal to end of interrupt processing in the deadlock avoidance mechanism 1
[0075] The coprocessor arithmetic control circuit 21 controls execution of a coprocessor instruction (S 10 ). In update of a data transfer parameter needing to be requested, the data transfer circuit 23 generates an interrupt signal. The data transfer circuit 23 supplies the generated interrupt signal to the processor core interrupt control circuit 12 in the processor core 10 (S 11 ).
[0076] The processor core interrupt control circuit 12 to which the interrupt signal has been supplied receives a current status of the processor core from the program control circuit 11 . When the status of the processor core is a status indicating that the coprocessor instruction is being executed, the processor core interrupt control circuit 12 supplies a processing cancellation request signal to the coprocessor interrupt control circuit 24 (S 12 ).
[0077] The coprocessor interrupt control circuit 24 that has received the processing cancellation request signal receives a current processing status of the coprocessor 20 from the coprocessor arithmetic control circuit 21 . The coprocessor arithmetic control circuit 21 decides from this processing status whether the coprocessor instruction currently being executed is canceled, or cannot be canceled (i.e., it is suspended) (S 13 ).
[0078] When the coprocessor instruction currently being executed can be canceled (S 13 : Yes), the coprocessor interrupt control circuit 24 instructs cancellation of execution of the coprocessor instruction to the coprocessor arithmetic control circuit 21 (S 14 ). Simultaneously with this, the coprocessor interrupt control circuit 24 supplies to the processor core interrupt control circuit 12 a processing cancellation determination signal indicating that cancellation was able to be performed.
[0079] Meanwhile, when the coprocessor instruction currently being executed cannot be canceled (S 13 : No), the coprocessor interrupt control circuit 24 instructs suspension of execution of the coprocessor instruction to the coprocessor arithmetic control circuit 21 (S 15 ). Furthermore, the coprocessor interrupt control circuit 24 stores an execution state of the coprocessor instruction in the suspension state storing register 243 (S 16 ). Simultaneously with this, the coprocessor interrupt control circuit 24 supplies to the processor core interrupt control circuit 12 a processing cancellation determination signal indicating that the coprocessor instruction has been suspended.
[0080] The processor core interrupt control circuit 12 that has received the processing cancellation determination signal stores a content of the determination. The processor core interrupt control circuit 12 then notifies the program control circuit 11 of the start of the interrupt processing. The program control circuit 11 starts execution of interrupt processing (S 17 ). Namely, the program control circuit 11 notifies the coprocessor arithmetic control circuit 21 of interrupt processing. The coprocessor arithmetic control circuit 21 notifies the data transfer circuit 23 of the received interrupt processing. As a result of this, the data transfer parameter 231 is set in the interrupt processing.
[0081] When the interrupt processing is ended, the coprocessor arithmetic control circuit 21 stops supply of a wait signal to the program control circuit 11 . The program control circuit 11 notifies the processor core interrupt control circuit 12 of the end of the interrupt processing. After this, the processor core interrupt control circuit 12 determines whether or not the coprocessor instruction has been canceled or has been suspended (S 18 ). When the coprocessor instruction has been canceled (S 18 : Yes), the processor core interrupt control circuit 12 performs reissue of the canceled coprocessor instruction through the program control circuit 11 (S 19 ). When the coprocessor instruction has been suspended (S 18 : No), the processor core interrupt control circuit 12 issues to the coprocessor interrupt control circuit 24 a processing resumption request signal to request resumption of the suspended coprocessor instruction.
[0082] When receiving the processing resumption request signal, the coprocessor interrupt control circuit 24 restores the execution state stored in the suspension state storing register 243 , and instructs resumption of the suspended coprocessor instruction (S 20 ).
[0083] Next, effects of the deadlock avoidance mechanism 1 pertaining to the embodiment will be described using FIGS. 8 and 3 , while comparing execution of general interrupt processing with processing of the deadlock avoidance mechanism 1 pertaining to the embodiment.
[0084] FIG. 8 shows a flow of execution of general interrupt processing. When interrupt processing is issued during execution of a coprocessor instruction, the interrupt processing is executed after the program waits for the end of execution of the coprocessor instruction. By execution of the interrupt processing, a value of the register used for arithmetic operation is saved, and the transfer parameter 231 is reset to the data transfer circuit 23 . The saved value of the register is then restored, and the program returns to execution of the coprocessor instruction.
[0085] Here, when execution of the coprocessor instruction cannot be ended unless after the data transfer parameter 231 is reset, interrupt processing cannot be executed. Namely, a deadlock state may occur.
[0086] FIG. 3 shows processing of the deadlock avoidance mechanism 1 pertaining to the embodiment. When interrupt processing is issued during execution of the coprocessor instruction, the deadlock avoidance mechanism 1 pertaining to the embodiment cancels or suspends the coprocessor instruction. After this, interrupt processing is immediately executed. When the coprocessor instruction is suspended, a processing status is saved in the suspension state storing register 243 . The data transfer parameter 231 is then reset. After that, the coprocessor instruction is resumed using data saved in the suspension state storing register 243 .
[0087] As described above, interrupt processing can be immediately executed before execution of the coprocessor instruction is ended. As a result of this, deadlock can be avoided.
[0088] When the coprocessor instruction is suspended, the deadlock avoidance mechanism 1 saves the execution state of the coprocessor instruction, in other words, writes it in the suspension state storing register 243 . The deadlock avoidance mechanism 1 restores the saved execution state, and resumes the coprocessor instruction. Namely, the deadlock avoidance mechanism 1 can resume the coprocessor instruction from the execution state in the coprocessor instruction having been suspended. As a result of this, resource mismatch inside the coprocessor can be avoided. Resource mismatch does not occur at the time of cancellation of the coprocessor instruction.
[0089] Furthermore, as described with reference to FIG. 1 , the deadlock avoidance mechanism 1 can reliably execute the coprocessor instruction issued once by reissuing the canceled coprocessor instruction.
[0090] As shown in the above-mentioned example, the deadlock avoidance mechanism 1 determines whether to cancel the coprocessor instruction according to whether or not a value has been written in the data memory 30 or the register. As a result of this, an illegal intermediate value can be prevented from remaining in the data memory 30 or the register by cancellation of the coprocessor instruction.
[0091] Here, a schematic view of the present invention is shown in FIG. 4 , and a configuration of the present invention will be described again. The processor core 10 includes: the program control circuit 11 ; and the processor core interrupt control circuit 12 . The coprocessor 20 includes: the coprocessor arithmetic control circuit 21 ; and the coprocessor interrupt control circuit 24 .
[0092] The processor core interrupt control circuit 12 issues a processing cancellation request signal to request cancellation of a coprocessor instruction being executed in the coprocessor 20 . The program control circuit 11 issues interrupt processing after issuing a cancellation request. The coprocessor arithmetic control circuit 21 holds an execution state of the coprocessor instruction. In receiving a processing cancellation request signal, the coprocessor interrupt control circuit 24 performs cancellation or suspension of the coprocessor instruction based on execution state information that the coprocessor arithmetic control circuit 21 holds. The coprocessor interrupt control circuit 24 saves the execution state of the coprocessor instruction when suspending the coprocessor instruction, and restores the saved execution state of the coprocessor instruction after the end of the interrupt processing.
[0093] Even in a configuration of FIG. 4 , interrupt processing can be promptly executed after the coprocessor instruction is canceled or suspended. When performing suspension, the coprocessor 20 saves the execution state of the coprocessor instruction, and restores the saved execution state of the coprocessor instruction after the end of the interrupt processing. As a result of this, interrupt processing can be immediately executed, and a problem of resource mismatch can be avoided.
[0094] It is to be noted that the present invention is not limited to the above-described embodiment, it can be appropriately changed without departing from the subject matter. For example, although the configuration including one coprocessor has been described in the above-mentioned example, the present invention can be adapted also to a semiconductor device including a plurality of coprocessors. In addition, although setting the data transfer parameter by interrupt processing has been described in the above-mentioned example, the present invention can be adapted also in a case of performing other processing by the interrupt processing.
INDUSTRIAL APPLICABILITY
[0095] An LSI for signal processing used for cell-phone terminals or AV equipment is included as a utilization example of the present invention.
[0096] This application claims priority based on Japanese Patent Application No. 2011-047907 filed on Mar. 4, 2011, and the entire disclosure thereof is incorporated herein.
REFERENCE SIGNS LIST
[0000]
1 Deadlock avoidance mechanism
10 Processor core
11 Program control circuit
12 Processor core interrupt control circuit
20 Coprocessor
21 Coprocessor arithmetic control circuit
22 Coprocessor arithmetic unit
23 Data transfer circuit
231 Data transfer parameter
24 Coprocessor interrupt control circuit
241 Control circuit
242 Cancellation determination circuit
243 Suspension state storing register
30 Data memory
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A processor core interrupt control circuit issues a request signal for requesting cancellation of a coprocessor instruction being executed at a coprocessor. A program control circuit issues interrupt processing after issuance of the cancellation request. A coprocessor computation control circuit retains the execution state of the coprocessor instruction. Upon receiving the processing cancellation request signal, a coprocessor interrupt control circuit performs cancellation or holding of the coprocessor instruction on the basis of execution state information retained by the coprocessor computation control circuit. The coprocessor interrupt control circuit evicts the execution state of the coprocessor instruction in the case of holding, and restores the execution state of the coprocessor instruction that had been evicted after completion of the interrupt processing.
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FIELD OF THE INVENTION
[0001] The present invention relates to energy storage devices, and specifically, to electrochemical capacitors, and to a method for preparing the same. In particular, the invention relates to the production of electrochemical capacitors or batteries based on aqueous electrolyte, and to an improved method of encapsulation thereof.
BACKGROUND OF THE INVENTION
[0002] There exists a need, in many different technological areas, for using electrochemical capacitors or batteries having small dimensions as energy storage devices.
[0003] In their most usual configuration, electrochemical capacitors, also known in the art as double layer capacitors, comprises a pair of flat electrodes saturated with a suitable electrolyte, wherein said electrodes are separated by a separating medium disposed therebetween. The separating medium, which may be either a porous sheet (known in the art as a separator), or a membrane, prevents the passage of electrical current in the form of electrons between the electrodes, while allowing ionic current to flow therebetween, due to the porous nature of the separator or the gel type matrix of the membrane. Each of the flat electrodes is placed on a surface of a suitable plate, said plate often being referred to in the art as a current collector. The appropriately sealed capacitor is electrically connected to a suitable load by means of external terminals.
[0004] The electrical capacity of the above-described system is attributed to the double-layer formed at the interface of the solid electrode and the electrolyte solution following the application of electrical potential on the pair of electrodes.
[0005] Electrochemical capacitors are generally divided into two distinct categories, according to the type of electrolyte used for preparing the electrode, which may be either an aqueous or organic electrolyte solution. The former type may generate up to 1.2 volt per cell, whereas the latter type typically provides about 2.5 to 3.0 volts per cell.
[0006] The operating voltage of electrochemical capacitors may be increased by assembling a plurality of individual capacitors described above in series, to obtain an arrangement known in the art as a bipolar capacitor. The art has suggested numerous types of electrochemical capacitors, attempting to improve, inter alia, the structural features of the capacitor, the chemical composition of the electrode material placed therein and of the adhesives used for sealing said capacitor, and the processes for fabricating the same.
[0007] Attempts to fabricate a single electrochemical capacitor and a bipolar arrangement based thereon have met with two main difficulties. The first difficulty is related to the attachment of the electrode to the current collector plate, or its deposition thereon. The second difficulty relates to the sealing of the circumferential region of the electrochemical capacitor, in order to prevent the seepage of the electrolyte solution from the electrochemical cell.
[0008] U.S. Pat. No. 3,536,963 discloses an electrochemical capacitor comprising electrodes which are made by mixing activated carbon particles with an aqueous electrolyte (e.g., sulfuric acid), to obtain a viscous paste, which is subsequently compressed to form the electrodes. Each of the electrodes is placed within an annular gasket which is affixed to a circular current collector plate, following which the separator is interposed between the electrodes.
[0009] U.S. Pat. No. 4,604,788 discloses a chemical composition for carbon paste electrodes comprising activated carbon particles, aqueous electrolyte and fumed silica, to provide a pumpable carbon-electrolyte mix. The fabrication of the capacitor involves the filling of an electrode cavity with the pumpable mixture, following which excess water is removed by a procedure described in the patent.
[0010] U.S. Pat. No. 6,212,062 discloses an electrochemical capacitor based on a solution of organic electrolyte, and a method for fabricating the same.
[0011] It is an object of the present invention to provide an improved, economically superior and industrially applicable method for manufacturing energy storage devices that comprise an aqueous electrolyte, such as electrochemical capacitors or batteries, which method is based on printing techniques.
[0012] It is another object of the present invention to provide a printable composition suitable for the preparation of electrodes for use in electrochemical capacitors, which printable composition may be easily and conveniently applied in the production of said capacitors by means of various printing techniques.
[0013] It is yet another object of the present invention to provide an electrochemical capacitor featuring novel electrode composition and improved structural characteristics.
SUMMARY OF THE INVENTION
[0014] In one aspect, the present invention provides a method for preparing energy storage devices that contain electrochemical cells, and specifically, double layer capacitors, comprising the steps of:
a) Providing a printable composition suitable for use as an electrode, comprising an active material, which is preferably in the form of carbon particles in admixture with an aqueous electrolyte; b) Placing a first template on one face of a current collector, wherein said first template is provided in the form of a sheet consisting of region(s) permeable to said printable composition, and masked region(s), non-permeable to said composition, wherein said masked region(s) of said first template include the margins thereof; c) Applying said printable composition through said first template onto said face of said current collector, thereby forming well-defined electrode region(s) thereon; d) Repeating steps b) and c) to produce a second current collector identical to the current collector of step (c); e) Placing a second template on a face of a separating medium which may be either a porous film or a membrane, wherein said second template is provided in the form of a sheet consisting of masked and non-masked region(s), wherein said second template is essentially complementary to said first template, such that said masked regions on said second template correspond with the permeable regions of the first template; f) Blocking the pores of said separating medium in those regions thereof which correspond with those regions of the current collector that have no electrodes printed thereon, and subsequently applying through the non-masked regions of said second template one or more adhesive materials onto said face of said separating medium; g) Attaching the adhesive face of said separating medium to the first current collector, such that the non-masked region(s) on said face of said separating medium coincide with the electrode(s) printed on the face of said first current collectors, with respect to position, geometric form and size; h) Repeating steps e) and f) with respect to the second face of said separating medium; i) Placing said second current collector on said second face of said separator, such that the non-masked regions on said second face of said separator coincide with the electrode(s) printed on the face of said second current collector, with respect to position, geometric form and size.
[0024] As used herein, the term “printable composition” refers to a mixture exhibiting the necessary physical properties for application in printing techniques, such as screen-printing, stencil-printing and roller-coating. The inventor has surprisingly found that it is possible to improve the flowability properties and the thixotropicity of the composition used to prepare the electrodes according to the invention, thus rendering said composition particularly suitable for screen-printing applications, by mixing the active components (e.g., the carbon material and the aqueous electrolyte) in specific weight ratios and by introducing into the composition a combination of specific additives.
[0025] According to a particularly preferred embodiment of the invention, the printable composition used for preparing the electrodes comprises high surface area activated carbon particles and an aqueous electrolyte, wherein the preferred weight ratio between said activated carbon particles and said aqueous electrolyte is in the range of 1:8 to 1:20, and most preferably in the range of 1:10 to 1:18.
[0026] Preferably, the printable composition used for preparing the electrodes according to the invention further comprises one or more additives selected from the group consisting of inorganic fillers, which are preferably chosen from among fumed silica, high surface area alumina, bentonites or other clays, glass spheres and ceramics; one or more hydroxy-containing compounds, such as alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 3 -C 7 alkynyl or C 3 -C 7 carbocyclic radical; and a salt. The inventor has surprisingly found that the presence of small amounts of one or more salts in combination with polyols reduces the viscosity of the printable composition. Thus, according to a particularly preferred embodiment, the printable composition comprises hydroxy-containing compound that is a polyol, and most preferably, propylene glycol, together with a small amount of a salt, which is preferably NaCl.
[0027] As used hereinabove, the term “separating medium” encompasses both separators and membranes according to their acceptable meanings in the art. Most preferably, the separating medium is provided in the form of a porous film known in the art as a separator.
[0028] Preferably, the method according to the invention comprises blocking the pores of said separator in those regions thereof which correspond with those regions of the current collector that have no electrodes printed thereon by applying through the non-masked regions of said second template a suitable sealant onto the face of said separator and rapidly curing said sealant to prevent passage thereof into those regions of the separator which need to be in contact with the electrode. Subsequently, one or more adhesive layers are applied onto the blocked regions of the separator, to allow the attachment of said separator to the current collector.
[0029] The fabrication method according to the invention provides a laminated structure, the external layers of which are the current collectors plates having well-defined electrode regions printed on their internal faces, and intermediate layer, which is a continuous separating medium interposed between the internal faces of the current collectors and affixed thereto by means of suitable adhesives, such that the electrodes are confined within said well-defined regions, the seepage of the electrolyte solution from said regions being prevented by virtue of the sealant blocking the pores of the separating medium and the adhesives provided along the perimeter of the electrodes.
[0030] The fact that the intermediate separator constitutes a continuous medium along the laminated structure described above is an important feature of the present invention, since, as may be readily appreciated, the electrochemical capacitors may be easily isolated from said laminated structure such that in each individual capacitor, the separator interposed between the electrodes is contiguous with the boundaries of the capacitor, and therefore, each individual capacitor is provided with an effective circumferential enclosure due to the sealant peripherally blocking the pores of the separator, and the adhesive layer(s) deposited on said sealant in the margins of said separator.
[0031] The electrochemical capacitor obtained by a preferred embodiment of the preparation method according to the invention is characterized by novel structural features, associated with the sequential blocking of the pores of the separator. Thus, in another aspect, the present invention provides an electrochemical capacitor comprising:
at least a pair of current collector plates that are placed in parallel to each other, flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size; wherein the pores in the peripheral region of the separator are impregnated with a suitable sealant, and wherein one or more layers of adhesives are deposited on said sealant.
[0036] Preferably, the sealant blocking the pores of the separator in the electrochemical capacitor according to one preferred embodiment of the present invention is made of a printable, rapidly curable material, and is most preferably UV curable epoxy.
[0037] The electrochemical capacitor obtained by a preferred embodiment of the preparation method according to the invention is characterized by novel chemical features, associated with the composition of the electrode. Thus, in another aspect, the present invention provides an electrochemical capacitor comprising:
at least a pair of current collector plates that are placed in parallel to each other, flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size; and wherein the electrode comprises carbon particles, aqueous electrolyte, inorganic filler selected from the group consisting of fumed silica, high surface area alumina, bentonites, glass spheres and ceramics and one or more hydroxy-containing compound(s), which are preferably alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 3 -C 7 alkynyl or C 3 -C 7 carbocyclic radicals, and optionally an inorganic salt, which is preferably selected from the group of alkali halides. Preferably, the inorganic filler is fumed silica, the hydroxy-containing compound is a polyol, which is preferably propylene glycol, and the salt is NaCl.
[0042] In another aspect, the present invention relates to bi-polar electrochemical capacitor comprising, as a basic cell unit, the electrochemical capacitor disclosed above.
[0043] All the above and other characteristics and advantages of the present invention will be further understood from the following illustrative and non-limitative description of preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 shows a current collector before and after the deposition of electrodes thereon by the method of the present invention.
[0045] FIG. 2 shows a separator before and after the partial masking of well-defined regions thereof by the method of the present invention.
[0046] FIGS. 3 a and 3 b provide sectional views of laminated structures obtainable according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] The method for preparing an electrochemical capacitor according to the present invention involves the preparation of a printable composition comprising carbon material, an aqueous electrolyte and preferably one or more additives selected from the group consisting of fumed silica and hydroxy-containing compounds which are preferably alcohols or polyols.
[0048] Preferably, the printable composition used to prepare the electrodes according to the present invention comprises carbon particles having specific surface area above 800 m 2 ·g −1 , and more preferably above 1200 m 2 ·g −1 . Suitable carbon particles include, but not limited to, activated carbon or activated charcoal and carbon black. Methods for preparing activated carbon suitable for use in the preparation of electrodes for electrochemical capacitors are known in the art (see, for example, U.S. Pat. No. 6,310,762). Commercially available activated carbon for use according to the present invention is, for example, Black Pearl carbon 2000 manufactured by Cabot. The percentage of the carbon material of the total weight of the printable composition is in the range of 4 to 10 (wt %), and more preferably in the range of 5 to 9 (wt %).
[0049] The printable composition used to prepare the electrodes according to the present invention comprises an aqueous electrolyte, which may be either acidic or alkaline solution. Preferred electrolytes are strong or weak acids such as sulfuric acid, phosphoric acid and hydrobromic acid, most preferred being an aqueous solution of sulfuric acid. The weight percentage of the aqueous solution of the electrolyte of the total weight of the printable composition is in the range of 80 to 96 (wt %), and more preferably in the range of 85 to 95 (wt %), with the weight ratio between the carbon material and said aqueous electrolytic solution being above 1:8, and more preferably between 1:10 to 1:18.
[0050] The printable composition used to prepare the electrodes according to the present invention comprises inorganic filler having thickening and thixotropic properties selected from the group consisting of fumed silica, high surface area alumina, bentonites or other clays, glass spheres and ceramics, most preferred being fumed silica, which is amorphous silicon dioxide having high external surface area. Commercially available fumed silica includes, for example, CAB-O-SIL™ M-5 (CAS No. 112945-52-5). The weight percentage of the inorganic filler of the total weight of the printable composition is in the range of 0.1% to 4%, and more preferably in the range of 0.5% to 2.5%.
[0051] The printable composition used to prepare the electrodes according to the present invention preferably comprises a compound containing one or more hydroxy groups, and more specifically, alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 2 -C 7 alkynyl or C 3 -C 7 carbocyclic radicals, or a mixture of such hydroxy-containing compounds. Most preferred are polyols such as 1,2-ethanediol or 1 , 2 -propandiol (i.e, propylene glycol). The percentage of the hydroxy-containing compound(s) of the total weight of the printable composition is in the range of 0.1 to 20 (% wt), and more preferably in the range of 0.3% to 10%.
[0052] It has been unexpectedly found that the presence of alkali halide salt in an amount of about 0.2 to 5 (wt %) of the total weight of the printable composition, improves the flowability properties of said composition.
[0053] Other additives that can be used in the preparation of the printable composition according to the present invention may be selected from the group consisting of metal oxides (e.g., oxides of platinum, titanium and ruthenium), thickening and thixotropic agents, surface-active agents, wetting agents, emulsifiers (e.g., fish oil), polymers and copolymers such as polyvinylacetate (PVA), polymethyl methacrylate (PMMA), polyethylene glycol (PEG), PAA, Carbomer, gelatin, water based adhesives, quinones or polyquinones. Graphite and carbon in the form of carbon fibers, fullerenes and buckeyballs may also be used in the preparation of the printable composition.
[0054] The printable composition according to the invention may be prepared by mixing together the solid constitutes (i.e., the carbon material and the inorganic filler), and subsequently gradually adding the liquids comprising the aqueous electrolyte and the hydroxy-containing compound, (i.e., the alcohol(s) or polyol(s)) to the solid mixture, optionally together with the salt, while continuously vigorously mixing the blend to obtain a uniform composition having paste-like consistency. However, the printable composition may also be prepared by a different order of operations, such as by adding the fumed silica into a mixture of the carbon material, the electrolyte solution and the alcohol(s) or polyol(s).
[0055] FIG. 1 schematically illustrates the process of forming well-defined electrode regions on a current collector plate by means of screen-printing technique. It should be noted, however, that other printing techniques, such as stencil printing, may also be applied for depositing the electrodes onto the current collector.
[0056] Referring now to FIG. 1 , current collector plate 1 is made of a conductive material that is chemically inert to the aqueous electrolyte contained in the electrode. The current collector may be provided in the form of a metal foil, such as aluminum foil, plated metal or metal coated with a protective oxide. Alternatively, the current collector is a polymeric sheet, such as polyethylene or Polytetrafluoroethane (Teflon), loaded with conductive particles such as carbon black, graphite, metallic or plated metallic particles. In another embodiment, the current collector has a multilayer structure comprising alternating layers of suitable polymers, metal foils and carbon or graphite, or similar combinations. The thickness of the current collector is preferably in the range of 10 μm to 150 μm.
[0057] Template 2 is provided in the form of a mesh or stencil suitable for use in printing techniques, wherein said mesh or stencil consists of regions 3 permeable to the printable composition, and masked regions 4 , non-permeable to said composition, wherein each of said permeable regions has a well-defined geometrical form corresponding to the form of the final electrochemical capacitor to be produced. For the purpose of illustration, sixteen separated non-masked, permeable regions having a square shape are shown in the figure, although, of course, a different number of non-masked regions of other shapes, such as rectangular or circular shapes, is also applicable. Typically, in case that the non-masked, permeable regions are in the form of a square, the side thereof has a size in the range of 0.5 to 60 mm, more preferably 5 to 20 mm. An important feature of the template is that its margins 5 are always masked.
[0058] The template 2 may be prepared by masking commercially available screen (40 to 250 mesh) according to the desired pattern by methods well known in the art.
[0059] Current collector 1 is placed on the vacuum surface of a screen-printing device (not shown), wherein template 2 is used as the screen. The printable composition according to the present invention is screen-printed through template 2 onto one face of the current collector 1 . Numeral 11 shows the resulting current collector, having sixteen well-defined, separated electrode regions 12 thereon. The thickness of the electrode layer is typically about 10 to 120μ. The procedure described above is repeated in respect to a second current collector, to produce a second current collector having electrodes printed thereon.
[0060] FIG. 2 illustrates a preferred mode of blocking the pores of the separator in those regions thereof that correspond with those regions of the current collectors that have no electrodes printed thereon. It should be noted, however, that various techniques may be used according to the present invention in order to selectively block the pores of the separator in the desired regions, which techniques include impregnating said pores with a suitable sealant, or with a mixture of sealants, wherein said sealant(s) may optionally be carried in a liquid vehicle. The impregnation may be accomplished by means of screen-printing or spraying the sealant onto said regions.
[0061] Alternatively, a polymeric sheet may be placed on the separator, following which said sheet is selectively heated in the desired regions, such that the molten polymer flows into the pores in said regions.
[0062] Other techniques for blocking the desired regions of the separator include the application of heat and/or pressure, in order to cause the porous structure to collapse in said regions. Combinations of the above-described techniques are also applicable according to the present invention.
[0063] It may be appreciated that according to the present invention, the sealant needs to be rapidly curable, that is, the sealant must be capable of transforming from a flowable form into solid, non-flowable form, within a short period of time, in order to avoid its passage into those regions of the separator which need to be in contact with the electrode. Typically, the sealant needs to be cured within seconds or minutes, depending on the thixotropic properties thereof and the characteristics of the separator (e.g., material, pore size). The curing of the sealant may be accomplished by methods known in the art, such as UV, IR or microwave or heat drying curing, or by polymerizing the sealant monomer by other means.
[0064] FIG. 2 shows the selective blocking of the desired regions of the separator by means of screen-printing technique. Separator 6 used according to the present invention is provided in the form of an inert, porous, electronically non-conductive, ion-permeable film, made of material inert to the aqueous electrolyte contained in the electrodes. The separator may be a glass fiber sheet or may be made of polyethylene, polypropylene, polyester, cellulose, Teflon or PVDF, or a composite of a polymer and a suitable filler. Teflon or cellophane-made separators may be used in case of acidic or alkaline electrolyte, respectively. The thickness of the separator is in the range of 5 to 50μ and its porosity typically varies within the range of 30 to 80%.
[0065] A second template 7 is provided in the form of a screen or stencil suitable for use in printing techniques. The screen may be made of polyester, nylon, stainless steal or coated stainless. As shown in the figure, the screen consists of a plurality of separated masked regions 8 and a non-masked region 9 , such that said screen is essentially complementary to the first template 2 shown in FIG. 1 . The preparation of template 7 is carried out similarly to that of template 2 . The meshes of the template 7 must permit the penetration of the adhesive materials, which need to be screen printed onto the separator, into the pores of the separator. To this end, a mesh corresponding to about 20 cm 3 per square meter printing volume is generally satisfactory.
[0066] Separator 6 is placed on the vacuum surface of a screen-printing device (not shown) wherein template 7 is used as the screen. The pores of separator 6 are blocked by a suitable sealant that is screen-printed onto Separator 6 through template 7 . The resulting, partially blocked separator is indicated by numeral 10 , wherein the non-masked and blocked regions are indicated by numerals 13 and 14 , respectively. The sealant used may be selected from the group consisting of hot melt adhesives, solvent based adhesives, polyurethanes, silicones, cyanoacrylates, PVC adhesives, Acrylic adhesives, UV based adhesives, water based glues, polysulfides rubber or synthetic rubbers, phenolic resins pressure sensitive adhesives, UV cured pressure sensitive adhesives and solvent based pressure sensitive adhesives. Most preferably, epoxy that is based on UV curing is screen-printed onto the separator 6 , and is subsequently immediately cured by means of exposure to UV light.
[0067] Having cured the sealant used to block region 14 of separator 10 , one or more adhesive layers are screen-printed onto separator 10 through template 7 . Suitable adhesives may be selected from among the classes specified above.
[0068] The adhesive face of separator 10 is subsequently affixed to the first current collector, such that the non-masked regions 13 on said face of said separator coincide with the electrodes 12 printed on the face of said first current collectors, with respect to position, geometric form and size. The current collector and the separator may be pressed or laminated together in vacuum to exclude air voids. The structure obtained is placed on the vacuum table of a screen-printing device, with the separator facing upwardly, and the procedure described above regarding the blocking of the desired regions of the separator, and the subsequent application of adhesive layers onto the blocked regions is repeated with respect to the second face of the separator.
[0069] A second current collector is then affixed to the separator, to produce the laminated structure represented in FIG. 3 a . The laminated structure comprises external layers, which are the current collectors plates 11 having sixteen well-defined electrodes printed on their internal faces (not shown), and intermediate layer, which is a continuous separator 10 interposed between the internal faces of the current collectors 11 , said separator being impregnated with a suitable sealant, such that the pores of the separator are essentially blocked in those regions thereof which are not placed between the electrodes. The separator 10 is affixed to the current collectors 11 by means of adhesive layers 15 , 16 (shown in black in the figure).
[0070] It is apparent from the figure that the laminated structure according to the invention is sealed along its circumference by means of the sealant blocking the pores of separator 10 , and adhesive layers 15 and 16 deposited on said sealant. The existence of distinct layers of a sealant material blocking the pores of the separator and one or more adhesives deposited thereon, is an important feature of the laminated structure according to the invention, which feature may be detected by using optical means.
[0071] Individual electrochemical capacitors may be easily isolated from the laminated structure described in FIG. 3 a , such that each individual capacitor comprises a pair of current collectors having electrodes printed on their internal faces and a separator interposed therebetween, the geometric form and size of said separator being identical to the form and size of said current collector, said separator being contiguous with the boundaries of the capacitor. Each of the isolated capacitors obtained is capable of storing charge and may be used as an electric double-layer capacitor with a dielectric strength corresponding to about 0.7 to 1.0 volts. For many practical utilities, however, it is preferred to assembly together a plurality of laminated structures of FIG. 3 a to produce the bi-polar arrangement illustrated in FIG. 3 b . it should be noted, that each face of internally placed current collector plates 17 is provided with well-defined regions of electrodes (not shown) printed thereon. According to the bi-polar configuration, the electrodes printed on different faces of a given current collector are oppositely charged. The assembly of a plurality of laminated structures of the invention, to obtain the bi-polar configuration shown in FIG. 3 b , may be accomplished by methods known in the art.
[0072] The electrochemical capacitor according to the invention, either in its simplest form comprising one pair of current collectors having electrodes printed on their internal faces and a separator interposed therebetween, or in the bi-polar configuration, are isolated from the laminated structures of FIGS. 3 a and 3 b , respectively, and are subsequently packed within a suitable casing and connected to external terminals by methods well known in the art.
[0073] The following non-limiting working examples illustrate various aspects of the present invention.
EXAMPLES
Example 1
[0074] Preparing a Printable Composition for the Electrodes
Ingredients: Activated carbon Sulfuric acid Fumed silica
[0079] 6 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 1 gram of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained were added 93 grams of an aqueous solution of H 2 SO 4 (4M). Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 2
[0080] Preparing a Printable Composition for the Electrodes
Ingredients: Activated carbon Sulfuric acid Fumed silica Propylene glycol
[0086] 35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of an aqueous solution of H 2 SO 4 (3M) and 16 grams of propylene glycol. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 3
[0087] Preparing a Printable Composition for the Electrodes
Ingredients: Activated carbon Sulfuric acid Fumed silica butanol
[0093] 35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of an aqueous solution of H 2 SO 4 (2.5M) and 16 grams of butanol. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 4
[0094] Preparing a Printable Composition for the Electrodes
Ingredients: Activated carbon Sulfuric acid Fumed silica Propylene glycol Sodium chloride
[0101] 35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of aqueous solution of H 2 SO 4 (2M), 13 grams of propylene glycol and 3 grams of sodium chloride. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 5
[0102] Depositing Electrodes on Current Collectors
[0103] A current collector plate was placed on the vacuum table of a screen-rinting device provided with a polyester screen of 165 mesh, said screen having the form illustrated in FIG. 1 . The printable composition of example 4 was screen printed onto the one face of the current collector, to form sixteen separated electrodes thereon. The procedure was repeated in respect to a second current collector.
Example 6
[0104] Masking the Pores of a Separator and Depositing Adhesives Thereon
[0105] A separator was placed on the vacuum table of a screen-printing device provided with a polyester screen of mesh corresponding to 18 cc per m 2 (325 mesh), which screen has the form illustrated in FIG. 2 . UV curable epoxy (Vitralit 1712) was screen-printed onto the separator, which was immediately subjected to UV radiation, in order to rapidly cure the epoxy. The separator was placed again on the vacuum table of the screen-printing device, and a suitable adhesive (Diglyceretherbisphenol CH 2 OCHCH 2 O—C 6 H 4 C (CH 3 ) 2 —C 6 H 4 OCH 2 CHOCH 2 (Epon-828 manufactured by shell or GY-250 manufactured by Henkel), in combination with Polypropyletheramine (Aradur 76 manufactured by Henkel)) was screen-printed thereon using the mesh described above.
Example 7
[0106] Preparation of a Laminated Structure
[0107] The adhesive face of the separator obtained by Example 6 was affixed to the printed face of one of the current collectors according Example 5, and the procedure of Example 6 was repeated in respect to the open face of said separator, following which the second current collector was affixed thereto.
[0108] While specific embodiments of the invention have been described for the purpose of illustration, it will be understood that the invention may be carried out in practice by skilled persons with many modifications, variations and adaptations, without departing from its spirit or exceeding the scope of the claims.
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The invention relates to a double layer capacitor comprising: at least a pair of current collector plates that are placed in parallel to each other, flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size; wherein the pores in the peripheral region of the separator are impregnated with a suitable sealant, and wherein one or more layers of adhesives are deposited on said sealant in said peripheral region. Also provided are method involving printing techniques for preparing electrochemical cells based-energy storage devices, and printable composition suitable for the preparation of electrodes for electrochemical cells based-energy storage devices.
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BACKGROUND OF THE INVENTION
1. Description of the Prior Art
Resonant transmission lines, also commonly referred to as RF tank cavities or RF tank circuits have been built in the past in half-wave and quarter-wave types. These circuits usually require a plate blocking capacitor to insulate the high DC potential of an associated power amplifier anode from the cavity walls, and in addition, they require insulated mechanical sliding supports for tuning. Both the half-wave and quarter-wave cavities built along these principals are more costly and have less efficiency than the folded half-wave cavity which is the subject of the present invention. Due to the folded nature of this cavity, a plate blocking capacitor is not required, and the inner conductor of the cavity may be operated at a high DC as well as a high RF potential, since tuning is accomplished without contact whatsoever with this inner conductor.
2. Field of the Invention
The field of art to which this invention pertains is RF tank circuits for amplifier stages and, in particular, to such circuits for use with power transmitters. More particularly, this invention relates to the manner of forming the tank circuit in such a way as to improve the power and efficiency as well as to effect cost reductions in the unit.
SUMMARY OF THE INVENTION
It is an important feature of the present invention to provide a resonant transmission line or an RF tank circuit for a transmitter power amplifier stage.
It is another feature of the present invention to provide an RF tank circuit for a power amplifier stage with increased efficiency and having mechanical simplifications for cost reductions.
It is a principal object of this invention to provide a folded half-wave cavity as an RF tank circuit for a power amplifier stage of a transmitter.
It is also an object of the present invention to provide an RF tank circuit for a power amplifier stage wherein the half-wave cavity is folded into itself, such that tuning of the cavity can be accomplished without mechanical supports at points of high RF potential.
It is another object of the invention to provide an RF tank circuit as described above wherein a portion of the grounded segment of the cavity is folded into an ungrounded segment and has an adjustable tuning berrilium copper bellow which may be adjusted from a drive means outside the cavity to accomplish fine tuning.
These and other features, objects and advantages of the present invention will be understood in greater detail from the following drawings and associated descriptions wherein reference numerals illustrate a preferred embodiment.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a half-wave cavity using mechanical supports to adjust the transmission line and having sliding contacts between the movable sections of that line.
FIG. 2 is another prior art device which is a quarter-wave length cavity also using sliding plate tuning contacts for tuning the cavity to a desired frequency. Both the devices in FIGS. 1 and 2 have plate blocking capacitors to insulate the high voltage of the RF amplifier tube from the walls of the transmission line.
FIG. 3 is a sectional view of a folded half-wave cavity in accordance with the present invention which employs means for tuning the cavity without the use of sliding contacts. This cavity eliminates the necessity for a plate blocking capacitor since the section of the transmission line which is in contact with the anode of the tube has no sliding contacts and, in fact, is physically spaced from the external walls of the cavity.
FIG. 4 is a cross-section of the device of FIG. 3 taken along the lines IV--IV.
FIG. 5 is a detailed view of the third conductor, illustrating the mechanical means for adjusting a bellows at its lower end, and
FIG. 6 is a detailed view of the top of the folded half-wave cavity, showing the mounting means for coarse adjustment of the third conductor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a resonant transmission line or half-wave cavity for a power transmitter. The cavity of the present invention is simplified over the prior art, allows cost reductions and has increased efficiency for the power amplifier stage of a transmitter. All this is accomplished by an arrangement wherein the outer conductor is folded into itself such that the inwardly folded section, for a portion of the length of the cavity, is positioned axially centrally of the inner conductor. The inner conductor is mechanically and electrically coupled directly to the anode of the RF amplifier tube, and hence, is maintained at the same DC potential as the anode. This is possible since there are no contacts between this inner conductor and the external portions of the cavity.
The folded portion of the cavity extends axially inside the inner conductor and is in the form of a hollow sleeve which is affixed to a honeycomb structure vent at the uppermost edge of the outer conductor. The end of the hollow sleeve has a berrilium copper bellows which is expandable by a drive mechanism which extends axially within the sleeve. Berrilium copper has a high conductivity and a long-term flex rate and therefore is particularly suitable for such a bellows. By adjusting the bellows, the tune frequency may be adjusted within a 2 MHz bandwidth. Coarse frequency adjustment is accomplished by presetting the position at which the hollow sleeve mounts to the honeycomb structure at the top of the cavity. The sleeve may be coarse-adjusted by loosening a hose clamp and then resetting the sleeve to a desired position for the frequency of operation. This, together with the tuning available by the bellows, covers the entire FM broadcast band.
Prior to the present invention, many resonant transmission lines or cavities have been of the standard half-wave variety or of the quarter-wave length variety. In either case, the cavities have required sliding mechanical contacts at high RF potentials or currents in order to accomplish tuning. In addition, to assure that the sliding contacts were not at a high DC potential, the RF amplifier tube usually had a plate-blocking capacitor located between the anode of the tube and the transmission line which was affixed thereto. These designs (now being used) have comparatively less efficiency and considerably more complexity and more opportunity for failure than the device of the present invention. For example, in the prior art, the cavity was usually silver-plated to assure good contact with the sliding contacts. This is not needed in the device of the present invention.
Referring to the drawings in greater detail, the prior art device of FIG. 1 consists of an outer conductor 10 and an inner conductor 11. The inner conductor 11 has slidable sections 12 and 13. Section 13 is sleeve-like and fits inside the section 12. The device also has sliding plate tuning contacts as illustrated by numerals 14 and 15.
The inner conductor 11 is mounted to a cooling fin 16 for the anode of the RF amplifier tube 17. A plate blocking capacitor 18 is positioned between the anode fins and the inner surface of the inner conductor 11. This acts as a DC block for the high voltage associated with the plate of the RF amplifier tube; this voltage may be in the order of 10 KV. The plate-blocking capacitor is an expensive item and has been known to present reliability problems. A lower plate 19 as air spaces such as at 20 to allow for air cooling of the RF amplifier tube. The air is allowed to exit through a honeycomb-type structure at the top surface 21 of the cavity. The cavity is grounded externally as shown schematically at 22. In the case of FIG. 1 the cavity is tuned by using mechanical supports such as illustrated at 23 and 24. These supports may be in a variety of forms, however, they grasp the slidable section 13 of the inner conductor and by mechanical means which may extend through the wall of the outer conductor, they may be moved vertically up and down causing the section 13 to slide within the section 12, thereby changing the length of the cavity and adjusting the frequency of tuning.
The prior art structure shown in FIG. 2 is a quarter-wave length cavity having an outer conductor 25 and an inner conductor 26. The inner conductor 26 is mounted to the cooling fins 27 associated with the anode of an RF amplifier tube 28 but insulated therefrom by a blocking capacitor 29 such that the inner conductor 26 is not maintained at a high DC potential. The upper ends of the conductor are connected to a similar honeycomb structure 30, which allows for the free flow of cooling air through the cavity.
In this case, there is also a doughnut-shaped sliding plate tuning contact illustrated at 31. This contact may be connected to points exterior of the outer conductor 25, so that it may be moved up and down between the inner conductor and the outer conductor and thereby effect tuning of the device. As in the case of FIG. 1 increased complexity of the mechanical structure, plating, reduced efficiency and also the need for a blocking capacitor characterize this product.
FIGS. 3 and 4 show the device of the present invention which eliminates the above-mentioned disadvantages of the device of FIGS. 1 and 2. This device may be referred to as a folded half-wave cavity. It has an outer conductor 35 which is "in effect" folded. The outer conductor 35 electrically is connected to a honeycomb upper portion of the cavity shown at 36 which, in turn, is mounted to a hollow sleeve 37 which extends inside the cavity. This honeycomb structure and the mounting means for the sleeve 37 are shown in more detail in FIG. 6.
An amplifier tube 38, has copper or similar heat conducting fins 39 at its anode. By way of example, this may be a ceramic/metal power tetrode with an anode rated for 20 KW of dissipation such as an Eimac 8990/4CX20000A. Space for air flow is shown at 40 and 41 allowing cooling air to pass around the tube and through the honeycomb structure 36 at the top of the cavity. The cooling fins have an inner conductor 42 attached thereto. The inner conductor extends upwardly within the cavity to its top surface 43 which is spaced from the honeycomb structure 36. This inner conductor is removably connected by suitable contacts to the fins of the amplifier tube and therefore maintained at the same voltage as the anode. The high voltage DC is applied directly to the inner conductor at a point 44 which is at an RF voltage null point. The high voltage DC is applied through a coil 45 which has a lead passing through a feed thru capacitor 46 formed in the wall of the outer conductor 35. The connection of the high voltage to this line is shown as B+ at a circuit point 47.
The hollow sleeve 37 which in effect is the outer conductor folded into itself is mounted through a sleeve bracket 48, and it extends to a lower surface 49 inside the inner conductor 42. Coarse-tuning may be accomplished by loosening a hose clamp 48a by turning a screw 48b which, in effect, allows the degree of extension of the sleeve 37 inside the cavity to be adjusted.
Fine tuning is accomplished by the use of a berrilium copper bellows 50 which is affixed to the lower end of the sleeve 37. In the preferred embodiment herein a Robertshaw Controls Company "sylphon" bellows was used, which yielded a fine tuning bandwidth of approximately 2 MHz. Berrilium copper was selected for its high conductivity and long-term flex rate. The actual adjustment of the bellows is mechanically accomplished by means of a drive shaft 51 which extends inside the sleeve 37, as described further in connection with FIG. 5. The RF output is taken from the cavity through a coaxial line 60 which couples RF energy from the RF voltage null point.
FIG. 5 is a detail of the sleeve 37. The drive shaft 51 is connected to the lower end 52 of the bellows by a screw 51b. It is slidably held by a key 61 mounted in a keyway in a shaft guide 62. The shaft is threaded at 63 and is threaded into a sleeve 64. As the sleeve 64 is rotated, the shaft 51 is moved up or down, sliding within the keyway and within a lower guide 65. This causes the bellows 50 to compress or expand, respectively. The sleeve is rotated by rotating a flexible shaft 66 into a gear drive box 67, which may have a gear reduction to a rotating shaft 51a, which in turn is coupled, as shown, to rotate the sleeve 64. A suitable manual means 68 may be used to rotate the flexible cable 66, and hence, compress or expand the bellows, thereby accomplishing fine tuning of the cavity.
The honeycomb structure 36 as shown in FIG. 6 comprises a sandwich of a bottom plate 70, a honeycomb layer 71 and a top plate 72. The bottom and top plates have large holes 73 to permit air to flow through the structure 36. The bracket 48 is clamped between the plates 70 and 72 by bolts 74. As described above, a hose clamp 48a may be loosened to allow the sleeve 37 to be moved up or down for coarse tuning. When the proper position is found, the hose clamp is reset and then the bellows 50 is adjusted for fine tuning.
It will be apparent to those skilled in the art, once having seen and understood the above description, that various modifications may be accomplished without departing from the basic innovations which are described above and which are set forth in the following claims.
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An RF tank circuit for a transmitter power amplifier stage including a half-wave length "folded" coaxial transmission line as an anode tuning device. The tank circuit has a grounded outer conductor and an ungrounded inner conductor, the latter to be operated at a high RF potential. The outer conductor is connected electrically to a third conductor which is adjustably extensible into the ungrounded inner conductor, hence, suggesting a folded effect for the outer conductor and the third conductor in combination. The third conductor has a bellows which can be expanded or contracted by drive means disposed exteriorly of the cavity, thereby to fine-tune the cavity to a selected frequency. The third conductor has mounting means which permit its extension into the inner conductor to be variable, thus allowing for coarse adjustment of the bandwidth, prior to the fine-tuning accomplished by suitable bellows-drive controls.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 62/286,540, filed Jan. 25, 2016 and entitled Handrail Mounting Assembly, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to support brackets. More particularly, the invention relates to a support bracket for mounting a handrail.
BACKGROUND
[0003] Handrails are conventionally mounted along stairs, ramps, walkways and other areas to provide support for people moving through that area. Conventional handrail mounting systems require drilling of holes in a support structure, such as a wall or a post, making field adjustment difficult and also creating undesirable permanent changes to the support structure.
SUMMARY
[0004] An adjustable mounting assembly for mounting a handrail to a support structure comprises an adjustable bracket for mounting to the support structure and an orientable bracket arm for connecting a handrail seat to the adjustable bracket.
[0005] According to one aspect, a handrail mounting assembly, comprises an adjustable bracket comprising a first section and a second section coupled to the first section for encircling and mounting to a support structure, a bracket arm connected to the adjustable bracket using a threaded fastener and a handrail seat connected to the bracket arm for seating a portion of a handrail to connect the handrail to the support structure.
[0006] According to another aspect, a bracket for mounting a handrail to a post, comprises a first section and a second section. The first section forms an open seat for the post and comprises a base wall, a first side wall extending from and perpendicular to the base wall, a second side wall extending from the base wall and parallel to the first side wall to define the open seat, a plurality of first openings in the first and second side walls and a tapped opening in the base wall. The second section couples to the first section to enclose the open seat. The second section includes a plurality of second openings that align with the first openings to form passageways for receiving fasteners to adjustably connect the first section and the second section.
[0007] According to another aspect, a handrail mounting assembly comprises a bracket for attaching to a support structure, the bracket having a threaded through hole in a base wall, a bracket arm comprising a tubular barrel having an opening extending therethrough, a threaded fastener inserted into the opening of the bracket arm, the threaded fastener longer than the opening to that an end of the fastener protrudes from the bracket arm and into a threaded through hole in the bracket and a handrail seat connected to the bracket arm.
[0008] According to another aspect, a method of mounting a handrail to a post comprises the steps of attaching an adjustable bracket to the post by sandwiching the post between two sections of the adjustable bracket, tightening the adjustable bracket to set the position of the bracket on the post, orienting a bracket arm relative to the adjustable bracket, tightening the bracket arm to set the orientation of the bracket arm relative to the adjustable bracket, and attaching a handrail to a handrail seat connected to the bracket arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a handrail mounting assembly of one embodiment of the invention;
[0010] FIG. 2 is a side view of a first section of an adjustable bracket in the handrail mounting assembly of FIG. 1 ;
[0011] FIG. 3 is an end view of the first section of FIG. 2 ;
[0012] FIG. 4 is an end view of a second section of the adjustable bracket of the handrail mounting assembly of FIG. 1 ;
[0013] FIG. 5 is a side view of the second section of FIG. 4 .
DETAILED DESCRIPTION
[0014] A handrail mounting assembly can be easily adjusted and assembled. The invention will be described relative to certain illustrative embodiments, though the invention is not limited to the embodiments described herein.
[0015] FIG. 1 shows a handrail mounting assembly 12 for mounting a handrail (not shown) to a post 10 or other support structure. The handrail mounting assembly 12 comprises an adjustable bracket 20 , a bracket arm 40 extending from the adjustable bracket 20 and a handrail seat 60 for receiving a handrail to connect the handrail to the post 10 . In one embodiment, the adjustable bracket 20 is configured to attach to a square post, thought the invention is not so limited. The bracket 20 can be easily adjusted, as described below. The orientation of the bracket arm 40 can also be adjusted relative to the bracket to allow adjustment of the handrail.
[0016] Referring to FIGS. 2-4 , the illustrative adjustable bracket 20 comprises a first section 22 that mates with a second section 32 to attach to a post or other support structure. The illustrative first section 22 forms an open seat 18 for the post, comprising a base wall 23 , and two side walls 24 , 25 extending substantially perpendicular to the base wall 23 . Each side wall 24 , 25 includes two openings for a total of four openings, two of which, 26 , 27 are shown in FIG. 2 , for receiving fasteners. The openings 26 , 27 , are entirely contained within the side walls 24 , 25 and are preferably centered between outer and inner surfaces defining the side walls, and are parallel to the inner surfaces 64 , 65 of the side walls. The inner surfaces 64 , 65 sandwich the post 10 when the bracket is mounted to the post 10 . The illustrative side walls 24 , 25 are straight and parallel to each other, as are the openings 26 , 27 . The openings extend into the side walls 24 , 25 by a selected distance from the front face 28 .
[0017] In one embodiment, the width W b of the first section, the distance between side walls 24 , 25 , is about equal to the width W p of the post 10 to allow the post to slide into the space between the side walls. The depth D b of the bracket seat 18 formed between the side walls is approximately equal to or smaller than the depth D p of the post.
[0018] The base wall 23 also includes an opening 21 , which may be a tapped through hole, for connecting the bracket 20 to the bracket arm 40 .
[0019] The illustrative second section 32 comprises an end plate that spans the opening 18 formed between the two side walls 24 , 25 . The end plate 32 includes four openings 36 , 37 , 38 , 39 that align with the side wall openings 26 - 27 to form passageways for receiving a fastener to secure the end plate 32 to the bracket seat 22 . On the back side, the openings may be countersunk to accommodate the head of a fastener. The illustrative second section 32 is substantially planar, though alternatively, the second section may have a different shape, such as a u-shape with side walls that match the side walls of the first section.
[0020] In one embodiment, the openings 36 - 39 are slightly larger than the openings 26 , 27 in the first section 22 .
[0021] To mount the bracket 20 to the post 10 , the first section 22 is wrapped around the post. The, the second section 32 is placed over the post 10 with the openings 26 , 27 , 36 - 39 aligned to surround the post 10 . Fasteners, such as screws, are inserted into the passageways to connect the first section 33 to the second section 32 . The bracket 20 can be easily adjusted on the post by loosening the fasteners, and the bracket can be secured in place and by tightening the fasteners to lock the post 10 in the bracket seat 18 .
[0022] Referring back to FIG. 1 , the bracket arm 40 comprises a first section 41 and a second section 42 extending at an angle, shown as perpendicular, to the first section 41 . The first and second sections may be integral or separately-formed components. The first section comprises a tubular barrel including an opening 44 extending therethrough for a fastener 43 to connect the bracket arm 40 to the adjustable bracket 20 . The opening 44 has a seat at a first end of the tubular barrel to limit movement of the fastener 43 . The fastener 43 is longer than the opening 44 so that when the fastener head is seated in the seat of the opening 44 , the tip of the fastener 43 protrudes from the second end of the first section 41 . The protruding end of the fastener is inserted in the opening 21 in the bracket base wall 23 to connect the bracket arm 40 to the bracket 20 . The second section 42 of the bracket arm 40 forms a handrail seat connector to connect the handrail seat 60 to the bracket arm 40 .
[0023] The orientation of the bracket arm 40 relative to the bracket 20 is adjustable. The bracket arm 40 can rotate about the protruding end of the fastener, allowing orientation of handrail seat. After the bracket arm 40 is position in a desired orientation relative to the bracket 20 , the fastener 43 is tightened to lock the bracket arm 40 to the bracket 20 in the desired orientation. The fastener 43 can be loosened, and the orientation of the bracket arm changed, followed by re-tightening of the fastener 43 to change the orientation of the bracket arm 40 .
[0024] The illustrative handrail seat 60 is formed on the top of the second section of the bracket arm 40 and can be integral with the bracket arm 40 or separately-formed and attached. The handrail seat 60 is curved to match the profile of the bottom of a handrail and includes openings 62 , 63 to receive fasteners for fastening the rail to the handrail seat 60 . The handrail seat can have any suitable configuration for receiving and connecting a handrail to the bracket arm. For example, the handrail seat could be annular, or square to accommodate a square handrail. The handrail can be adjustable relative to the bracket arm 40 , if desired.
[0025] The illustrative handrail mounting assembly provides increased flexibility and reduced installation time by eliminating the need to drill, tap or punch openings in the post or other support structure in order to mount the handrail. The illustrative handrail mounting assembly allows for easy field adjustment of the assembly and-or handrail mounted thereto by simply loosening the components, adjusting and re-tightening the connections in the desired location and orientation.
[0026] The scope of the claims is not meant to be limited to the details of the described exemplary embodiments.
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A handrail mounting assembly comprises an adjustable bracket and an orientable bracket arm connected to a handrail seat. The adjustable bracket comprises two mating components that surround a post and lock together using fasteners extending through aligned openings in the two mating components. A bracket arm connected to the handrail seat includes an extending opening that aligns with a threaded opening in the adjustable bracket for receiving a fastener to connect the bracket arm to the bracket.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for preparing L-α-methylphenyl alanines by biochemical asymmetric hydrolysis of DL-α-methylphenyl alanine amides, in which a microbial enzyme catalyzing a hydrolysis of L-isomer of DL-α-methylphenyl alanine amides is utilized.
2. Description of the Prior Art
It is known in the art that pharmacological activities are possessed by L-α-methylphenyl alanines, but not D-α-methylphenyl alanines. For instance, L-3,4-dihydroxy-α-methylphenyl alanine, usually referred to as "methyl dopa", is a well-known excellent hypotensor, while D-3,4-dihydroxy-α-methylphenyl alanine has no hypotensor activity. Accordingly, effective optical resolution of chemically synthesized DL-α-methylphenyl alanines is an extremely important problem to be solved in the art.
Various optical resolution methods of the racemic mixture of α-methylphenyl alanines have been heretofore proposed, including physical methods, such as diastereomer methods or fractional crystallization methods, and biochemical methods, utilizing microorganisms.
Diastereomer methods are disadvantageous in that the yield of the desired product is low, the recovery of the desired product is troublesome, the resolution agent used is expensive, and the recovery of the resolution agent is not easy.
Fractional crystallization methods are disadvantageous in that the racemic mixture is often crystallized prior to crystallization of the desired optically active product even if crystals of the desired optically active product are seeded and that both the resolution rate (%) and the crystallization reproducibility of the desired optically active product are low.
In known biochemical resolution methods, N-succinyl or N-benzoyl derivatives of DL-α-methylphenyl alanines are used as substrates for asymmetric hydrolysis by microbial enzymes. These methods are, however, disadvantageous in that the synthesis of the substrates is troublesome, the reuse of the remaining substrates (i.e., D-derivatives) is difficult, and the yield of the desired product is low.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a biochemical method for resolution of DL-α-methylphenyl alanines eliminating the above-mentioned disadvantages in the prior arts, thereby effectively producing L-α-methylphenyl alanines.
Other objects and advantages of the present invention will be apparent from the description set forth hereinbelow.
In accordance with the present invention, there is provided a process for preparing an L-α-methylphenyl alanine having the general formula [I]: ##STR3## wherein R 1 and R 2 may be independently a hydrogen atom or lower alkyl group, or R 1 and R 2 may be alkylene groups combined together to form 5-through 8-membered rings, comprising the steps of:
(a) making a DL-α-methylphenyl alanine amide having the general formula [II]: ##STR4## wherein R 1 and R 2 are the same as defined above, interact with the culture product of a microorganism capable of producing enzyme catalyzing the hydrolysis of L-isomer of DL-α-methylphenyl alanine amide or the treated product thereof, whereby asymmetric hydrolysis of an L-α-methylphenyl alanine amide is effected; and
(b) separating the resultant L-α-methylphenyl alanines from the hydrolysis mixture.
DETAILED DESCRIPTION OF THE INVENTION
The term "the treated product" used herein means that the cells or broth separated from the cultivation mixture, or enzyme preparations including cell-free extract, crude enzyme and purified enzyme prepared from the cultivation mixture, the cells or broth, or the immobilized preparations derived from all of them.
Typical examples of the DL-α-methylphenyl alanine amides having the above-mentioned general formula [II] and usable as substrates in the present invention are as follows. It should be noted, however, that these substrates are not restrictive, but illustrative. ##STR5## DL-3,4-dihydroxy-α-methylphenyl alanine amide ##STR6## DL-4-hydroxy-3-methoxy-α-methylphenyl alanine amide ##STR7## DL-3,4-dimethoxy-α-methylphenyl alanine amide ##STR8## DL-3,4-methylenedioxy-α-methylphenyl alanine amide
These substrates may be readily prepared by, for example, reacting ammonium cyanide to phenylacetones to form the amino nitrile derivatives and hydrolyzing the nitrile group of the resultant amino nitrile derivatives in the presence of an acid.
The microorganisms usable in the present invention include any microorganisms which can produce enzyme catalyzing the hydrolysis of only L-isomer in a racemic mixture of DL-α-methylphenyl alanine amides, regardless of their taxonomical groups. Examples of the genus names of these microorganisms are listed in the following table, in which the typical species name of the microorganism belonging to each genus is also listed. However, it should be noted that the microorganisms which can be employed in the practice of the present invention are not limited to these specific examples. All the exemplified microorganisms are known and also readily available from the depositories of JFCC (Japanese Federation of Culture Collections of Microorganisms) such as IFO (Institute for Fermentation, Osaka, Japan) and IAM (Institute of Applied Microbiology, University of Tokyo, Tokyo, Japan), and NIHJ (National Institute of Health, Japan).
______________________________________ (1) Genus Rhizopus IFO-4768 Rhizopus chinensis (2) Genus Absidia IFO-4011 Absidia orchidis (3) Genus Aspergillus IFO-4068 Aspergillus niger var fermentarius (4) Genus Penicillium IFO-5692 Penicillium frequentans (5) Genus pullularia IFO-4464 Pullularia pullulans (6) Genus Fusarium IFO-5421 Fusarium roseum (7) Genus Gibberella IFO-5268 Gibberella fujikuroi (8) Genus Trichoderma IFO-4847 Trichoderma viride (9) Genus Gliocladium IFO-5422 Gliocladium roseum(10) Genus Cunninghamella IFO-4441 Cunninghamella elegans(11) Genus Actinomucor IFO-4022 Actinomucor repens(12) Genus Geotrichum IFO-6454 Geotrichum candidum(13) Genus Saccharomyces IFO-0505 Saccharomyces rouxii(14) Genus Shizosaccharomyces IFO-0346 Shizosaccharomyces pombe(15) Genus Pichia IFO-0195 Pichia polimorpha(16) Genus Hansenula IFO-0117 Hansenula anomala(17) Genus Debariomyces IFO-0023 Debariomyces hansenii(18) Genus Nadsonia IFO-0665 Nadsonia elongata(19) Genus Sporobolomyces IFO-0376 Sporobolomyces pararoseus(20) Genus Cryptococcus IFO-0378 Cryptococcus albidus(21) Genus Torulopsis IFO-0768 Torulopsis candida(22) Genus Brettanomyces IFO-0642 Brettanomyces anomalus(23) Genus Candida IFO-0396 Candida utilis(24) Genus Tricosporon IFO-0598 Tricosporon beigelii(25) Genus Rhodotorula IFO-0412 Rhodotorula minuta var texensis(26) Genus Mycobacterium Mycobacterium smegmatis NIHJ-1628 Mycobacterium avium chester IFO-3154 Mycobacterium phlei IFO-3158(27) Genus Nocardia IFO-3424 Nocardia asteroides(28) Genus Streptomyces IFO-3356 Streptomyces griseus(29) Genus Aerobacter IFO-3320 Aerobacter aerogenes(30) Genus Alcaligenes IAM-1517 Alcaligenes viscolactis(31) Genus Flvobacterium IAM-1100 Flavobacterium arborescens(32) Genus Bacillus IFO-3026 Bacillus subtilis(33) Genus Agrobacterium IFO-13262 Agrobacterium tumefaciens(34) Genus Micrococcus IFO-3242 Micrococcus flavus(35) Genus Sarcina IFO-3064 Sarcina aurantiaca(36) Genus Arthrobacter IFO-3530 Arthrobacter simplex(37) Genus Brevibacterium IFO-12071 Brevibacterium ammoniagenes(38) Genus Pseudomonas Pseudomonas iodinum IFO-3558 Pseudomonas fluorescens IFO-3081(39) Genus Lactobacillus IFO-3322 Lactobacillus casei(40) Genus Streptococcus IFO-3434 Streptococcus lactis(41) Genus Clostridium IFO-3346 Clostridium acetobutyricum(42) Genus Enterobacter IFO-3317 Enterobacter aerogenes(43) Genus Ustilago IFO-5346 Ustilago zeae______________________________________
Among these microorganisms, microorganisms belonging to genera Trichoderma, Nocardia, Mycobacterium, Bacillus, Rhizopus, Candida, Hansenula, Streptomyces, Aerobacter, Arthrobacter, Pseudomonas, Gibberella, Torulopsis, Enterobacter, and Ustilago are especially useful in the practice of the present invention,
In the practice of the present invention, the above-mentioned microorganisms can be made to interact with the DL-α-methylphenyl alanine amides in the form of the cultivation mixture thereof, the cells or broth separated from the mixture, or enzyme preparations including cell-free extract, crude enzyme, and purified enzyme prepared from the cultivation mixture, the cells or the broth according to conventional methods. The cells, or enzyme may be immobilized on carriers in the practice of the present invention.
The enzyme which can catalyze the hydrolysis of L-isomer of DL-α-methylphenyl alanine amides is not clearly understood, but it would seem amidase, without prejudice to the invention.
Examples of the carriers usable in the present invention are natural products such as alginic acid, carrageenan, collagen, cellulose, acetylcellulose, agar, cellophane, and collodion and synthetic polymer substances such as polyacrylamide, polystyrene, polyethylene glycol, polypropylene glycol, polyurethane, and polybutadiene. The immobilization of the cells or enzyme on the carrier can be carried out in a conventional methods under moderate conditions so that the activity of the enzyme is not impaired.
The suitable reaction temperature of the asymmetric hydrolysis according to the present invention can be within the range of from 20° C. through 50° C. However, in order to minimize the decrease in the enzymatic activity, the use of the reaction temperature of from 25° C. through 40° C. is economically advantageous. The suitable reaction time of the asymmetric hydrolysis according to the present invention can be within the range of from 5 through 50 hours. However, the reaction time can be shortened by raising the reaction temperature or by increasing the amount of the enzymes used. Furthermore, the reaction can be generally carried out under a pH of 5 through 10, more preferably 7 through 9.
The amount of the microorganisms employed in the practice of the present invention is desirably in a weight ratio of from 0.01 through 2, in terms of the freeze dried cells, based on the weight of the DL-α-methylphenyl alanine amides. In the case where the cultivation mixtures of the microorganisms, enzyme preparations prepared from the mixtures or cells, or the immobilized products thereof are employed, the amount thereof can be determined in terms of the amount of the freeze dried cells. The suitable concentration of the substrate, i.e., DL-α-methylphenyl alanine amides in the reaction mixture is generally within the range of from 1% through 40% by weight, desirably 5% through 30% by weight.
According to the present invention, the asymmetric hydrolysis reaction is stopped after the hydrolysis of L-α-methylphenyl alanine amides proceeds at the conversion rate of almost 100%, and then, L-α-methylphenyl alanines and D-α-methylphenyl alanine amides are separately isolated from the reaction mixture. This separation can be readily carried out by using any conventional separation techniques, such as fractional crystallization and solvent extraction, D-α-methylphenyl alanine amides are not affected by the action of the microorganisms in the above-mentioned asymmetric hydrolysis and, therefore, almost all D-α-methylphenyl alanine amides can be recovered from the racemic mixture. The D-α-methylphenyl alanine amides thus recovered can be readily hydrolyzed by using any conventional techniques, for example, by heating in the presence of an aqueous acid or alkaline solution. The resultant D-α-methylphenyl alanines are treated by sodium hypochlorite to form phenyl acetones, which, in turn, are again usable as starting material for the synthesis of the above-mentioned substrate.
The present invention has the advantages in that, as compared with known biochemical processes, (1) the substrates to be used can be readily prepared at a low cost, (2) the separation of the desired product from the remaining substrate (i.e., D-isomer) in the reaction mixture is not difficult and the recovered D-isomer can be used again as the starting material for the synthesis of the substrate, and (3) the optical purity and yield of the desired product are high.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to, the following examples wherein the yield of L-α-methylphenyl alanines is calculated from the following equation. ##EQU1##
EXAMPLES 1 THROUGH 15
One hundred ml of a culture medium having a pH of 7.0 and containing 5% by weight of glycerol, 5% by weight of corn steep liquor, 0.5% by weight of ammonium sulfate, and 1 ml of a mixture of inorganic salts was charged into a shaking flask. The inorganic salts mixture was prepared by dissolving 20 g of MgSO 4 .7H 2 O, 5 g of FeSO 4 .7H 2 O, 2 g of CaCl 2 , 0.2 g of MnCl 2 .4H 2 O, 0.1 g of NaMoO 4 .2H 2 O, and 0.1 g of NaCl in 1,000 ml of distilled water. After sterilizing the content of the flask, 2 loopfuls each of the microorganisms listed in Table 1 below were inoculated from an agar slant and, then, the reciprocal shaking culture (or incubation) was carried out at a temperature of 30° C. for 65 hours.
Thereafter, 2 g of DL-3,4-dimethoxy-α-methylphenyl alanine amide was added to the flask and, then, the reciprocal shaking culture was carried out at a temperature of 30° C. for 48 hours. The cells were removed from the reaction mixture by centrifugation or filtration. The filtrate was analyzed with a high speed liquid chromatograph. Thus, the yield of 3.4-dimethoxy-α-methylphenyl alanine thus obtained was determined.
No specific optical rotation data of L- or D-3,4-dimethoxy-α-methylphenyl alanine were available in literatures. Accordingly, the resultant 3,4-dimethoxy-α-methylphenyl alanine was converted to N-acetyl-3,4-dimethoxy-α-methylphenyl alanine according to a method described in the following Example 16. From the specific optical rotation data of the N-acetyl derivatives available in literatures, it was confirmed that the 3,4-dimethoxy-α-methylphenyl alanine obtained in each Example was L-isomer.
The results obtained in Examples 1 through 15 are shown in the following Table 1.
TABLE 1______________________________________ Formed L-3,4-dimethoxy- α-methylphenyl alanine Specific optical rotation [α].sub.DExample Microorganism used yield (%) (C = 1, H.sub.2 O)*______________________________________1 Enterobacter aerogenes 42 -50° IFO-33172 Bacillus subtilis 74 -49° IFO-30263 Candida utilis 36 -51° IFO-03964 Rhizopus chinensis 30 -47° IFO-47685 Trichoderma viride 28 -46° IFO-48476 Nocardia asteroides 49 -48° IFO-34247 Mycobacterium smegmatis 86 -52° NIHJ-16288 Streptomyces griseus 33 -49° IFO-33569 Ustilago zeae 66 -51° IFO-534610 Aerobacter aerogenes 51 -52° IFO-332011 Arthrobacter simplex 23 -49° IFO-353012 Pseudomonas fluorescens 94 -53° IFO-308113 Gibberella fujikuroi 31 -47° IFO-526814 Torulopsis candida 17 -45° IFO-076815 Hansenula anomala 30 -44° IFO-0177______________________________________ *Specific optical rotation of N--acetyl compound
EXAMPLE 16
From the culture mixture of Mycobacterium avium chester (IFO-3154) prepared in the same manner as in Example 1, the cells were collected by centrifugation and, then, washed twice with distilled water.
The washed cells were added to 100 ml of a 0.1 M phosphate buffer solution having a pH of 7.0 and containing 2 g of DL-3,4-dimethoxy-α-methylphenyl alanine amide. The resultant mixture was incubated at a temperature of 30° C. for 20 hours.
After completing the reaction, the cells were removed from the reaction mixture by centrifugation. The resultant reaction mixture thus obtained was analyzed by a high speed liquid chromatography. As a result, the resultant reaction mixture contained 950 mg of L-3,4-dimethoxy-α-methylphenyl alanine (yield=95%) and 1030 mg of D-3,4-dimethoxy-α-methylphenyl alanine amide.
The reaction mixture was extracted by 200 ml of benzene. Thus, 970 mg of the unreacted oily D-3,4-dimethoxy-α-methylphenyl alanine amide having a specific optical rotation [α] D of +20.5° (c=1, methanol) was recovered.
On the other hand, the water layer after the extraction was adjusted to a pH of 2.0 by using hydrochloric acid. The resultant solution was vaporized to dryness. Thus, 980 mg of L-3,4-dimethoxy-α-methylphenyl alanine hydrochloride crystal having a specific optical rotation [α] D of +5.4° (c=1, methanol) was obtained. Thereafter, the resultant crystal was dissolved in 20 ml of iso-propanol, and 2.0 ml of triethylamine and 2.0 l of acetic anhydride were added. The resultant solution was allowed to stand overnight and was concentrated under reduced pressure. The residue was dissolved in 2.0 ml of water, and the pH of the resultant solution was adjusted to 2.0 by using concentrated hydrochloric acid. The resultant solution was extracted with ethyl acetate, and the extracted ethyl acetate layer was dried and distillated under reduced pressure. Thus, 800 mg of L-N-acetyl-3,4-dimethoxy-α-methylphenyl alanine crystal having a melting point of 182° C. through 185° C. and a specific optical rotation [α] D of -53.0° (c=1, methanol) was obtained.
The above-obtained specific optical rotation value is identical to that of L-N-acetyl-3,4-dimethoxy-α-methylphenyl alanine in literatures. Accordingly, it was confirmed that the resultant acetyl compound was L-acetyl compound and the 3,4-dimethoxy-α-methylphenyl alanine obtained above was also the L-isomer having an optical purity of 96.4%. Furthermore, the 3,4-dimethoxy-α-methylphenyl alanine amide recovered above was the D-isomer.
EXAMPLE 17
The washed cells of Mycobacterium avium chester (IFO-3154) prepared in the same manner as in Example 16 were washed with cold acetone. Thus, acetone dried cells were obtained.
DL-3,4-dimethoxy-α-methylphenyl alanine amide was dissolved in distilled water and substrate solutions having various concentrations listed in Table 2 below and having a pH of 7.0 were prepared.
The above-mentioned acetone dried cells were added to 10 ml of the substrate solutions in such an amount that the weight ratio of the dried cells to the substrate were 0.2. Then, the reaction was carried out at a temperature of 30° C. for 20 hours. The resultant reaction mixture was analyzed to determine the yield of L-3,4-dimethoxy-α-methylphenyl alanine by using a high speed liquid chromatograph.
The results are shown in Table 2 below.
TABLE 2______________________________________Concentration of substrate(DL-3,4-dimethoxy-α-methylphenyl Yield of L-3,4-dimethoxy-α-alanine amide) methylphenyl alanine(% by weight) (%)______________________________________1 1002 1005 10010 10020 8630 7240 49______________________________________
EXAMPLE 18
The washed cells of Mycobacterium avium chester (IFO-3154) prepared in the same manner as described in Example 16 were freeze dried.
The freeze dried cells were added to 10 ml of distilled water containing 10% by weight of DL-3,4-dimethoxy-α-methylphenyl alanine amide and having a pH of 7.5 in a weight ratio of the cells to the substrate listed in Table 3 below. The resultant mixture was incubated at a temperature of 30° C. for 20 hours. The reaction mixture was analyzed to determine the yield of L-3,4-dimethoxy-α-methylphenyl alanine by a high speed liquid chromatograph.
The results are shown in Table 3 below.
TABLE 3______________________________________Freeze dried cells Yield of L-3,4-dimethoxy-α-Substrate methylphenyl alanine(Weight ratio) (%)______________________________________0.01 680.05 890.1 970.5 1001.0 100______________________________________
EXAMPLE 19
Fifty mg of the freeze dried cells of Mycobacterium avium chester (IFO-3154) prepared in the same manner as described in Example 18 were suspended in 5 ml of 0.2 M phosphate buffer solution having a pH of 7.0 and, then, the cells were disrupted under cooling by using a French press (20,000 psi). The resultant mixture was centrifuged under 20,000×g for 30 minutes. To 5 ml of the supernatant solution thus obtained, 100 mg of DL-3,4-dimethoxy-α-methylphenyl alanine amide was added, and the pH of the mixture was adjusted to 7.5. Thereafter, the mixture was incubated at a temperature of 30° C. for 20 hours.
The reaction mixture thus obtained was analyzed by a high speed liquid chromatograph. L-3,4-dimethoxy-α-methylphenyl alanine was obtained at a yield of 85%.
EXAMPLE 20
To 5 ml of the cell-free extract of Mycobacterium avium chester (IFO-3154) prepared in the same manner as described in Example 19, ammonium sulfate was added. The ammonium sulfate precipitate obtained at a saturation of 25% through 75% of ammonium sulfate was collected by centrifugation. Then, 5 ml of 0.2 M phosphate buffer solution containing 100 mg of DL-3,4-dimethoxy-α-methylphenyl alanine amide and having a pH of 7.5 was added thereto. The mixture was incubated at a temperature of 30° C. for 20 hours.
The reaction mixture thus obtained was analyzed by a high speed liquid chromatograph. As a result, L-3,4-dimethoxy-α-methylphenyl alanine was obtained at a yield of 58%.
EXAMPLE 21
Ten ml of the cell-free extract of Mycobacterium avium chester (IFO-3154) prepared in the same manner as in Example 19 was passed through a column having a diameter of 1.5 cm and a height of 65 cm and packed with Sephadex G-75. Thus, fractions having the enzyme activity were collected. These fractions were concentrated by using a semipermeable membrane method to a volume of 5 ml.
Thereafter, 100 mg of DL-3,4-dimethoxy-α-methylphenyl alanine amide was added thereto. The mixture was incubated at a temperature of 30° C. for 20 hours.
The reaction mixture was analyzed by a high speed liquid chromatograph. As a result, L-3,4-dimethoxy-α-methylphenyl alanine was obtained at a yield of 48%.
EXAMPLE 22
The washed cells (corresponding to 1.0 g of the freeze dried cells) of Mycobacterium avium chester (IFO-3154) prepared in the same manner as in Example 16 were suspended in 15 ml of 0.1 M phosphate buffer solution having a pH of 7.0 and, then, 3.75 g of acrylamide monomer, 0.2 g of N,N'-methylene bisacrylamide (i.e., crosslinking agent), 2.5 ml of a 5% aqueous 3-dimethylamino propionitrile solution (i.e., polymerization promotor), and 2.5 ml of aqueous potassium persulfate solution (i.e., polymerization initiator) were added and mixed with one another. The mixture was allowed to stand at a temperature of 25° C. for 1 hour. Thus, the gellation of the mixture was completed.
The gel thus obtained was crushed and washed with water. The resultant immobilized product (i.e., gel particles having a particle diameter of 0.2 through 0.5 mm) was packed into a column having a diameter of 2 cm and a height of 50 cm. Thereafter, distilled water containing 10% by weight of DL-3,4-dimethoxy-α-methylphenyl alanine amide and having a pH of 7.5 was passed through the column at a temperature of 30° C. from the top of the column at a space velocity (SV) of 0.2/hr.
In this continuous reaction, the yield of L-3,4-dimethoxy-α-methylphenyl alanine was maintained at 85% or more until the reaction time became 200 hours.
EXAMPLES 23 THROUGH 25
One hundred mg of the freeze dried cells of Pseudomonas iodinum (IFO-3558) prepared in the same manner as described in Example 18 were suspended in 50 ml of 0.1 M phosphate buffer solution having a pH of 7.5. Various DL-3,4-dihydroxy-α-methylphenyl alanine amides were added to the resultant suspension and the incubation was carried out at a temperature of 30° C. for 20 hours. After removing the cells, the yields of the resultant L-3,4-dihydroxy-α-methylphenyl alanines were determined by means of a high speed liquid chromatograph.
The unreacted D-3,4-dihydroxy-α-methylphenyl alanine amides were recovered from the reaction mixtures according to the same method as described in Example 16. The L-3,4-dihydroxy-α-methylphenyl alanines thus obtained were isolated.
The results thus obtained are shown in Table 4 below.
TABLE 4__________________________________________________________________________Example ProductNo. Substrate Chemical name Yield % Specific optical rotation__________________________________________________________________________23 DL-3,4-dihydroxy- L-3,4-dihydroxy- 83 [α].sub.D -4.5°α-methyl- α-methylphenyl (c = 2, 0.1 N HCl)phenyl alanine alanineamide24 DL-4-hydroxy- L-4-hydroxy-3- 92 [α].sub.D +159°3-methoxy- methoxy-α- (c = 0.5, 0.25 M CuSO.sub.4)α-methyl- methylphenylphenyl alanine alanineamide25 DL-3,4-methylene- L-3,4-methylene- 94 [α].sub.D +22.0°dioxy-α-methyl- dioxy-α-methyl- (c = 1, 0.1 N HCl)phenyl alanine phenyl alanineamide__________________________________________________________________________
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Biochemical optical resolution of DL-α-methylphenyl alanines in which DL-α-methylphenyl alanine amides are interacted with the culture products, or their treated products, of a microorganism capable of producing amidase is described. L-α-methylphenyl alanines having the general formula (I): ##STR1## wherein R 1 and R 2 may be independently a hydrogen atom or lower alkyl groups, or R 1 and R 2 may be alkylene groups combined together to form 5 through 8-membered rings is produced by the steps of:
(a) making a DL-α-methylphenyl alanine amide having the general formula (II): ##STR2## wherein R 1 and R 2 are the same as defined above, interact with the culture product of a microorganism capable of producing enzyme catalyzing the hydrolysis of L-isomer of DL-α-methylphenyl alanine amides or the treated product thereof, whereby asymmetric hydrolysis of an L-α-methylphenyl alanine amide is effected; and
(b) separating the resultant L-α-methylphenyl alanines from the hydrolysis mixture.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2005-093931, filed on Mar. 29, 2005, prior Japanese Patent Application No. 2005-093937, filed on Mar. 29, 2005, and prior Japanese Patent Application No. 2005-093938, filed on Mar. 29, 2005, and the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a vaporizing device to vaporize liquid, and a liquid absorbing member used therein.
[0004] 2. Background of the Invention
[0005] In recent years, there have been seen vigorous studies and developments for fuel batteries to realize high energy use efficiency. The fuel battery makes fuel react with oxygen contained in ambient air electrochemically and takes out electric energy directly from chemical energy. The fuel batteries have been placed as a promising energy source. As for a fuel for used in the fuel battery, hydrogen can be mentioned. However, there is a problem that since hydrogen takes a gaseous state at ambient temperatures, it has difficulty in handling and storage. When a liquid fuel such as alcohols and gasoline is used, a system for storing the liquid fuel can be made comparably small in size, but the fuel and water vapor must be heated to a high temperature for reaction to create hydrogen which is used to generate electricity.
[0006] For example, in Japanese Laid-open Patent Specification No. 2004-18357, in order to create hydrogen from the liquid fuel and water, a technique in which the liquid fuel and water are vaporized in an evaporating apparatus, and a gas mixture of the liquid fuel and water supplied from the evaporating apparatus is reformed into hydrogen in a reformer, is disclosed.
[0007] However, as a vaporizing apparatus is made smaller in size, it becomes more difficult to vaporize fuel steadily or quantitatively.
SUMMARY OF THE INVENTION
[0008] The present invention has been made to solve the above problem and has an object to steadily vaporize fuel in a vaporizing device.
[0009] In order to solve the above problem, a vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; and a heater to heat the side of the other end portion of the liquid absorbing member to vaporize the liquid.
[0010] Preferably, the liquid absorbing member has one of a felt core, a ceramic porous core, and a fiber core.
[0011] Preferably, the liquid absorbing member has a closely overlapping unit to cover a peripheral surface of the liquid absorbing member and to leave the one end portion and the other end portion of the liquid absorbing member exposed.
[0012] Preferably, the closely overlapping unit has elasticity.
[0013] Preferably, the closely overlapping unit has heat shrinkability.
[0014] Preferably, the liquid absorbing member is made of a material having heat conductivity of 0.5 W/m·K or less.
[0015] Another vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; and an electrically heating wire to heat the side of the other end portion of the liquid absorbing member to vaporize the liquid.
[0016] Another vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; a heater to heat the side of the other end portion of the liquid absorbing member to vaporize the liquid; and a gas permeable film provided at the other end portion of the liquid absorbing member.
[0017] Preferably, the gas permeable film includes polytetrafluoroethylene or polyvinylidene-fluoride.
[0018] A liquid absorbing member of the present invention comprises: an elastic closely overlapping unit which exposes the liquid absorbing member at one end portion and the other end portion, and allows liquid to move from the one end portion to the other end portion of the liquid absorbing member under influence of a capillary action.
[0019] Preferably, the closely overlapping unit has heat shrinkability.
[0020] Preferably, the liquid absorbing member includes a material having heat conductivity of 0.5 W/m·K or less.
[0021] Another liquid absorbing member of the present invention comprises: a gas permeable film which allows liquid that moves from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action, to penetrate through in a gaseous state.
[0022] Preferably, the gas permeable film includes polytetrafluoroethylene or polyvinylidene-fluoride.
[0023] According to the present invention, the heater can heat the liquid that moves from the one end portion of to the other end portion of the liquid absorbing member, and vaporize the liquid stably.
[0024] Additionally, the vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; a case to house the liquid absorbing member; and a pressure controlling section to regulate a difference between a pressure at the side of one end portion of the liquid absorbing member and a pressure at the side of the other end portion of the liquid absorbing member to be constant.
[0025] The liquid may include fuel, or fuel and water.
[0026] The pressure controlling section may regulate pressure at the side of the one end portion of the liquid absorbing member and the pressure at the side of the other end portion of the liquid absorbing member to be equivalent with each other.
[0027] Preferably, the vaporizing device further comprises a supplying section to supply liquid to the side of the one end portion of the liquid absorbing member; and a measuring section to measure the pressure at the side of the one end portion of the liquid absorbing member and the pressure at the side of the other end portion of the liquid absorbing member.
[0028] The measuring section may measure a pressure applied to liquid at the side of the one end portion of the liquid absorbing member and a pressure of gas at the side of the other end portion of the liquid absorbing member.
[0029] A vaporizing method of the present invention comprises a step to keep a difference between two pressures constant, wherein the two pressures are a pressure at the side of the one end portion of a liquid absorbing member and a pressure at the side of the other end portion of the liquid absorbing member, which allows liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action.
[0030] A pressure applied to liquid at the side of the one end portion of the liquid absorbing member and a pressure of gas at the side of the other end portion of the liquid absorbing member may be measured, and the pressure applied to liquid at the side of the one end portion of the liquid absorbing member may be regulated so that the difference between the pressure at the side of the one end portion of the liquid absorbing member and the pressure at the side of the other end portion of the liquid absorbing member is kept constant.
[0031] The pressure at the side of the one end portion of the liquid absorbing member and the pressure at the side of the other end portion of the liquid absorbing member may be made to be equivalent with each other.
[0032] According to the present invention, vaporization of liquid can be performed stably or quantitatively.
[0033] A vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; and a case to house the liquid absorbing member with a cavity left at the one end portion of the liquid absorbing member.
[0034] Preferably, a cross-sectional area of the cavity is larger than an area of end surface of one end portion of the liquid absorbing member.
[0035] Preferably, the case is provided with an introduction hole leading to the cavity, and a cross-sectional area of the introduction hole is smaller than a cross-sectional area of the cavity.
[0036] A vaporizing device of the present invention comprises: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; and a case to house the liquid absorbing member with a cavity left at the one end portion of the liquid absorbing member, wherein the case is provided with an introduction hole leading to the cavity, a cross-sectional area of the cavity is larger than an area of end surface of one end portion of the liquid absorbing member, and a cross-sectional area of the introduction hole is smaller than the cross-sectional area of the cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a perspective view of a vaporizing device 1 ;
[0038] FIG. 2 is a cross-sectional view of the vaporizing device 1 ;
[0039] FIG. 3 is a block diagram of power generating device 50 using the vaporizing device 1 ;
[0040] FIG. 4 is a schematic view showing the vaporizing device 1 , micro-reactor 52 and fuel battery 53 ;
[0041] FIG. 5 is a block diagram of power generating device 50 A using the vaporizing device 1 ;
[0042] FIG. 6 is a block diagram of power generating device 50 B using the vaporizing device 1 ;
[0043] FIG. 7 is a schematic view showing experimental equipment for studying a relationship between pressure at the discharging side of the vaporizing device 1 and amount of vaporization;
[0044] FIG. 8 is a graph showing the result of the experiment performed by the experimental equipment shown in FIG. 7 ;
[0045] FIG. 9 is a schematic view showing another experimental equipment for studying a relationship between pressure at the discharging side of the vaporizing device 1 and amount of vaporization; and
[0046] FIG. 10 is a graph showing the result of the experiment performed by the experimental equipment shown in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Here, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Although various kinds of preferred technical restrictions are added to the embodiments described hereinafter, the embodiments shall by no means restrict the scope of the invention to the embodiments and drawings described below.
[0048] FIG. 1 is a perspective view illustrating a vaporizing device 1 , and FIG. 2 is a cross-sectional view of the vaporizing device 1 taken along its central line.
[0049] As illustrated in FIGS. 1 and 2 , the vaporizing device 1 comprises a liquid absorbing member 2 having nature of absorbing liquid therein, an internal tube 3 partially covering the peripheral surface of the liquid absorbing member 2 , an external tube 4 covering the peripheral surface of the internal tube 3 , an inlet nipple 5 through which liquid flows into the liquid absorbing member 2 , an outlet nipple 6 through which the liquid absorbed in the liquid absorbing member 2 flows out in a vaporized state, an approximate tube-shaped inlet case 7 , an approximate tube-shaped outlet case 8 , an o-ring 9 to seal a clearance formed between the outlet nipple 6 and outlet case 8 , a gas permeable film 10 with moisture permeability, and a heating coil 11 to heat the liquid absorbed in the liquid absorbing member 2 to the extent that the liquid vaporize.
[0050] The liquid absorbing member 2 is a core material in the shape of a rod, more specifically, of a column shape. The liquid absorbing member 2 is inserted into the internal tube 3 with the external peripheral surface kept close to the inner peripheral surface of the internal tube 3 . The liquid absorbing member 2 is longer than the internal tube 3 . One end surface of the liquid absorbing member 2 aligns with one end portion of the internal tube 3 or sticks out of the one end portion of the internal tube 3 , and the other end surface of the liquid absorbing member 2 sticks out of the other end portion of the internal tube 3 . The gas permeable film 10 is formed on the other end surface of the liquid absorbing member 2 . The internal tube 3 serves so as to keep the liquid absorbing member 2 from breaking apart, when the liquid absorbing member 2 is handled, and also to protect the same from getting dirty.
[0051] The liquid absorbing member 2 is inserted into the external tube 4 with the internal tube 3 interposed between them, and the external tube 4 is kept close to the internal tube 3 . One end surface of the liquid absorbing member 2 is placed inside the one end portion of the external tube 4 , and the other end surface of the liquid absorbing member 2 sticks out of the other end portion of the external tube 4 .
[0052] A part of the tube-shaped inlet nipple 5 is pressed into one end portion of the external tube 4 with a clearance left between the inlet nipple 5 and the liquid absorbing member 2 . As a result, a cavity 12 is formed between the inlet nipple 5 and liquid absorbing member 2 . The external diameter of the inlet nipple 5 , concerning the portion which has been pressed into the external tube 4 , is approximately equivalent to an external diameter of the internal tube 3 with the liquid absorbing member 2 inserted therein, and is also approximately equivalent to a diameter of the cavity 12 (internal diameter of the external tube 4 ). In case where either of the liquid absorbing member 2 or internal tube 3 , or both of them have elasticity, the liquid absorbing section 2 can be easily inserted into the external tube 4 . The cavity 12 is slightly larger in diameter than the liquid absorbing member 2 by an amount equivalent to wall thickness of the internal tube 3 , and the cross-sectional area of the cavity 12 which is parallel to the one end surface of the liquid absorbing member 2 is larger than the one end surface of the liquid absorbing member 2 . In case the liquid absorbing member 2 absorbs liquid, the lateral side of the liquid absorbing member 2 swells in the direction of diameter, whereby a clearance between the internal tube 3 and the external tube 4 is eliminated, and displacement of the internal tube 3 with respect to the external tube 4 is prevented. Therefore, the cavity 12 will not be eliminated due to displacement of the liquid absorbing member 2 .
[0053] The inlet nipple 5 is provided with an introduction hole 15 along its central line, and the introduction hole 15 penetrates through the inlet nipple 5 from front end to the other side of the inlet nipple 5 . The diameter of the introduction hole 15 is smaller than the diameter of the cavity 12 and is also smaller than the diameter of the liquid absorbing member 2 . The cross-sectional area of the cavity 12 which is parallel to the one end surface of the liquid absorbing member 2 is larger than the cross-sectional area of the introduction hole 15 .
[0054] The end portion of the liquid absorbing member 2 , which is provided with the gas permeable film 10 , is pressed into the tube-shaped outlet nipple 6 . One end portion of the internal tube 3 is also inserted into the outlet nipple 6 , and is sandwiched between the outlet nipple 6 and liquid absorbing member 2 . In addition, an introduction portion of the outlet nipple 6 is inserted into the other end portion of the external tube 4 , whereby the external tube 4 connects the outlet nipple 6 and the inlet nipple 5 by means of the liquid absorbing member 2 .
[0055] The outlet nipple 6 is provided with a discharge hole 16 along its central line, and the discharge hole 16 extends from the front end of the outlet nipple 6 to a hollow where the liquid absorbing member 2 is inserted.
[0056] On the portion of the outlet nipple 6 where the liquid absorbing member 2 is pressed into, a heating coil 11 is wounded around. The portion of the outlet nipple 6 where the liquid absorbing member 2 is pressed into is formed in a flange.
[0057] A cylindrically-shaped inlet case 7 receives in its hollow the external tube 4 , internal tube 3 , and inlet nipple 5 . A part of the external tube 4 is sandwiched between the inlet case 7 and inlet nipple 5 . A part of the external tube 4 and a part of the internal tube 3 are sandwiched between the inlet case 7 and the liquid absorbing member 2 . A small hole leading to the hollow is formed at one end surface of the inlet case 7 , through which hole the front end of the inlet nipple 5 sticks out of the one end surface of the inlet case 7 .
[0058] A cylindrically-shaped outlet case 8 receives in its hollow the external tube 4 , internal tube 3 , liquid absorbing member 2 , heating coil 11 , and inlet case 7 . A small hole leading to the hollow is formed at one end surface of the outlet case 8 , through which hole the front end of the outlet nipple 6 sticks out of the one end surface of the outlet case 8 . The portion of the outlet nipple 6 which is sticking out is inserted in the o-ring 9 , which serves to seal at the one end surface of the outlet case 8 .
[0059] The outlet case 8 is provided on its peripheral surface with a fixing unit 18 . The fixing unit 18 is formed with a screw hole 19 to screw shut.
[0060] Next, materials and material qualities of the liquid absorbing member 2 , internal tube 3 , external tube 4 , inlet nipple 5 , outlet nipple 6 , inlet case 7 , outlet case 8 , o-ring 9 , gas permeable film 10 , and the heating coil 11 will be described.
[0061] The liquid absorbing member 2 has minute holes formed inside, and is capable of absorbing liquid. The liquid absorbing member 2 has heat-resistance at least up to the boiling-point of the liquid which is imported therein. A felt core, ceramic porous core, fiber core, and the like can be mentioned as the material used for the liquid absorbing member 2 . As for the materials of the felt core, chemical fiber felt, heat-resistant fiber felt, needle felt, resin finishing felt, formed felt, wool felt and the like can be applied. Examples of the fiber core include inorganic fiber (for example, glass fiber and asbestos) or organic fiber (for example, organic resin formed as fiber). As for the ceramic porous core, inorganic powder (for example, aluminum compound, and silicon compound) which is sintered into a porous material, and inorganic powder which is coagulated with a binding material can be used. The liquid absorbing member 2 preferably has an affinity for fuel liquid such as water and ethanol.
[0062] The heating coil 11 comprises an electric heating material, and generates heat using electricity. For instance, a nickel-cobalt wire subjected to an oxide coating treatment can be used as the heating coil 11 .
[0063] The liquid absorbing member 2 is heated at the other end surface which in on discharging side, by the heating coil 11 , but it is preferable that the whole body of the liquid absorbing member 2 is not warmed up but only the portion of the liquid absorbing member 2 which is heated becomes warm locally. Therefore, it is preferable that such structure is reluctant to release heat. More specifically, it is preferable that a material (bulk material) of the liquid absorbing member 2 has thermal conductivity of 0.5 W/m·K or less.
[0064] It is preferable that the internal tube 3 has rubber elasticity, and may have heat shrinkability. Further, it is preferable that the internal tube 3 in a natural state, in which the internal tube 3 is not inserted with liquid absorbing member 2 , has an inner diameter smaller than the diameter of the liquid absorbing member 2 , and the inner diameter of the internal tube 3 increases by insertion of the liquid absorbing member 2 . Examples of the internal tube 3 are a tube of radiation cross-linking flexible polyolefin resin (Sumitube A, manufactured by Sumitomo Electric), a tube of polyolefin (HSTT, manufactured by Panduit Corp.), or a tube of fluorine resin (TFE-2X, TFE-2XSPSW19, TFE-2XSPSW 13, manufactured by Hagitec).
[0065] The external tube 4 has rubber elasticity. Here, the liquid absorbing member 2 held in the internal tube 3 is inserted into the external tube 4 . However, the liquid absorbing member 2 can also be inserted directly into the external tube 4 without using the internal tube 3 . In this case, it is preferable that the external tube 4 has heat shrinkability.
[0066] The inlet nipple 5 can be made of a resin, a metal, or ceramic.
[0067] It is preferable that the outlet nipple 6 is made of a metal having thermal conductivity of 100 W/m·K or higher, to conduct heat easily from the heating coil 11 to the liquid absorbing member 2 . As for the material of the outlet nipple 6 , for example, copper (in the case of pure copper, thermal conductivity is 380 W/m·K), copper alloy (in the case of brass, thermal conductivity is 146 W/m·K), and aluminum alloy (in the case of aluminum, thermal conductivity is 230 W/m·K) can be mentioned. The surface of the outlet nipple 6 can be applied with a nickel plating treatment.
[0068] It is preferable that the inlet case 7 and outlet case 8 have low heat conductivity and heat resistance to prevent heat generated by the heating coil 11 from being released outside. Therefore, the heat conductivity is preferably 0.5 W/m·K or less. Examples of materials of the inlet case 7 and outlet case 8 are PPS (PolyPhenylene Sulfide), PEEK (PolyEtherEtherKetone), PES (PolyEtherSulfone), PBI (PolyBenzImidazole), and the like. The heat resistance temperature (deflection temperature under load 1.82 MPa) and heat conductivity of PPS, PEEK, PES and PBI are given in the following Table 1.
TABLE 1 Heat resistance temperature (deflection temperature under Heat conductivity Material load 1.82 MPa (° C.)) (W/m · K) PPS 108 0.33 PEEK 140 0.25 PES 203 0.18 PBI 435 0.40
[0069] The gas permeable film 10 has hydrophobic property on the surface, and contains minute holes inside, whereby the film 10 is given a property that does not allow liquid to penetrate through the film 10 but allows gas to penetrate through the film 10 . As for examples of material used for the gas permeable film 10 , PTFE (PolyTetraFluoroEthylene) and PVDF (PolyVinyliDeneFluoride) can be mentioned. In case where the gas permeable film 10 is made of PTFE, it became clear through an experiment that PTFE film allows gas (vapor) to penetrate through, where thickness of the film is 200 μm and average pore diameter is 5 μm. Meanwhile, PTFE thin film with thickness of 135 μm and average pore diameter of 1.2 μm does not allow gas to penetrate through. In addition, PTFE thin film with thickness of 172 μm and average pore diameter of 3 μm also does not allow gas to penetrate through. Therefore, it is preferable that the average pore diameter of the gas permeable film 10 is 5 μm or larger.
[0070] Next, operation of the vaporizing device 1 will be described.
[0071] When a voltage is applied to the heating coil 11 , the heating coil 11 generates heat. In case liquid is fed into the introduction hole 15 in this state, the liquid pools in the cavity 12 , and becomes absorbed by the liquid absorbing member 2 through its one end surface. The liquid absorbed through the one end surface is sucked toward the other end surface by capillary action and is vaporized by heat of the heating coil 11 . The gas vaporized at the end portion of the discharging side of the liquid absorbing member 2 penetrates through the gas permeable film 10 , and is discharged outside through the discharge hole 16 . In case a pressure of the liquid to be supplied is made equivalent to a pressure of the discharged gas, amount of liquid becoming vaporized per unit time increases, and even in case where the pressure of the liquid or the pressure of the gas is changed, the amount of liquid becoming vaporized per unit time is kept almost constant. Therefore, it is preferable to measure the pressure of the discharged gas and the pressure of the supplied liquid and to adjust the pressure of the discharged gas and the pressure of the supplied liquid by flow rate control unit, according to the measured values so that the pressure of the discharged gas is kept equal to the pressure of the supplied liquid.
[0072] Air bubbles may be contained in the liquid supplied through the introduction hole 15 . However, since the cross-sectional area of the cavity 12 formed between the introduction hole 15 and the one end surface of the liquid absorbing member 2 is larger than the area of the one end surface of the liquid absorbing member 2 , the air bubbles are diffused inside the cavity 12 . Therefore, the one end surface of the liquid absorbing member 2 is not covered entirely with the air bubbles, and the liquid absorbing member 2 is not prevented from absorbing the liquid.
[0073] Since the air bubbles accumulated in the cavity 12 are not absorbed into the liquid absorbing member 2 as fast as the liquid, the air bubbles burst in the cavity 12 , or gets gradually absorbed into the liquid absorbing member 2 and becomes discharged from the discharge hole 16 provided at the opposite side. The cavity 12 serves as a buffer for temporarily storing the air bubbles. Since the cross-sectional area of the introduction hole 15 is smaller than that of the cavity 12 , a rate at which the air bubbles are stored in the cavity 12 is lower than a rate at which the air bubbles are absorbed into the liquid absorbing member 2 through its one end surface. Therefore, the one end surface of the liquid absorbing member 2 is not covered entirely with the air bubbles, and therefore even in case the air bubbles are sucked by the one end surface, the liquid absorbing member 2 is not prevented from absorbing the liquid. Consequently, the liquid absorbing member 2 is prevented from ceasing the vaporization of the fuel.
[0074] Since the liquid is vaporized inside the liquid absorbing member 2 provided with minute holes, abrupt boiling of the liquid can be suppressed. Particularly, since the other end portion at discharging side of the liquid absorbing member 2 is heated by the heating coil 11 and the liquid absorbing member 2 has low heat conductivity, the liquid is vaporized neither in the middle portion nor in one end portion at the introduction side of the liquid absorbing member 2 , but is vaporized at the other end portion at the discharging side of the liquid absorbing member 2 . In case a gas is generated in the middle portion or in the one end portion at the introduction side of the liquid absorbing member 2 , the pressure of the generated gas reduces liquid absorbability by capillary action of the liquid absorbing member 2 . However, such disadvantage can be prevented.
[0075] In addition, the heating coil 11 does not contact the liquid absorbing member 2 directly, and the outlet nipple 6 is provided between the heating coil 11 and the liquid absorbing member 2 . Therefore, the liquid absorbing member 2 is not heated locally, and the liquid absorbing member 2 is prevented from being damaged locally by heat.
[0076] Since the liquid absorbing member 2 is inserted into the internal tube 3 and the internal tube 3 is kept in close contact with the liquid absorbing member 2 , the gas generated inside the liquid absorbing member 2 does not burst out from the peripheral surface of the liquid absorbing member 2 . Therefore, the gas is prevented from bursting out toward the one end surface of the liquid absorbing member 2 , through a clearance between the peripheral surface of the liquid absorbing member 2 and the internal tube 3 .
[0077] Further, since the liquid absorbing member 2 is inserted into the internal tube 3 , the liquid contacts directly with the liquid absorbing member 2 only at its one end surface on the rearward side, and the liquid absorbability of the liquid absorbing member 2 increases at the one end surface on the rearward side. In addition, the gas generated in the other end surface at the discharging side (discharge hole 16 ) of the liquid absorbing member 2 is prevented from returning to the introduction side (introduction hole 15 ). Since the internal tube 3 allows both end portions of the liquid absorbing member 2 to be exposed, and covers the peripheral surface of the liquid absorbing member 2 in close contact, a clearance where a capillary action can occur is not left between the peripheral surface of the liquid absorbing member 2 and the internal tube 3 . Therefore, the gas inside the liquid absorbing member 2 is prevented from moving toward the peripheral surface of the liquid absorbing member 2 to return to the introduction side along the clearance, and is also prevented from remaining in the clearance. Consequently, the gas inside the liquid absorbing member 2 is pushed out from the introduction side to the discharging side by the liquid moving under influence of capillary action. Specifically, since the internal tube 3 has heat shrinkability, adhesion of the internal tube 3 to the liquid absorbing member 2 is enhanced by heat of the heating coil 11 , whereby the advantages of the above arrangement become prominent.
[0078] In addition, since the external tube 4 is sandwiched between the inlet case 7 and the liquid absorbing member 2 , air-tightness and water-tightness of the inlet case 7 are ensured by the external tube 4 . The inlet nipple 5 and the outlet nipple 6 are pressed into both end portions of the external tube 4 , respectively. Therefore, the liquid supplied from the introduction hole 15 can be vaporized and the gas can be discharged through the discharge hole 16 even in the absence of the inlet case 7 and outlet case 8 . However, the air-tightness and water-tightness are further enhanced and heat loss is also reduced by existence of the inlet case 7 and outlet case 8 . In particular, since the inlet case 7 and the outlet case 8 are made of a material having low heat conductivity and heat resistance, heat loss can be suppressed.
[0079] Further, since the gas permeable film 10 is formed on the other end surface at the discharging side of the liquid absorbing member 2 , the liquid does not ooze out from the gas permeable film 10 toward the discharge hole 16 , and scattering of the liquid due to abrupt boiling is prevented particularly.
[0080] Examples of application of the vaporizing device 1 will be described with reference to FIGS. 3 and 4 .
[0081] FIG. 3 is a block diagram showing power generating device 50 using the vaporizing device 1 . FIG. 4 is a schematic view showing the vaporizing device 1 , micro-reactor 52 , and fuel battery 53 .
[0082] The power generating device 50 comprises a fuel reservoir 51 , the micro-reactor 52 , fuel battery 53 and fluid equipment 60 in addition to the vaporizing device 1 .
[0083] The micro-reactor 52 has a reformer 54 , a carbon monoxide remover 55 , and a combustor 56 built in. When the vaporizing device 1 is loaded to the micro-reactor 52 , the outlet nipple 6 reaches the reformer 54 .
[0084] In the fuel reservoir 51 , water and liquid fuel (for example, alcohols such as methanol and ethanol, or gasoline) are stored separately. The fuel reservoir 51 is provided with an air filter 81 . In the following description, it is assumed that methanol is used as the fuel.
[0085] The fluid device 60 comprises pumps 61 , 64 , 68 , ON-OFF valves 62 , 65 , control valves 69 , 71 , and flow sensors 63 , 66 , 70 , 72 , 73 . Further, the fluid device 60 is provided with an introduction pipe 74 connected to a water drain outlet of the fuel reservoir 51 and an introduction pipe 75 connected to a fuel drain outlet of the fuel reservoir 51 .
[0086] The pump 61 sucks water from the fuel reservoir 51 and sends water to the vaporizing device 1 . The ON-OFF valve 62 controls ceasing and/or starting of water flow, and the flow sensor 63 measures a flow rate of the water. The pump 64 sucks liquid fuel from the fuel reservoir 51 and sends liquid fuel to the vaporizing device 1 . The ON-OFF valve 65 controls ceasing and/or starting of liquid fuel flow and the flow sensor 66 measures a flow rate of the liquid fuel. The vaporizing device 1 is supplied with water and liquid fuel in a mixed state.
[0087] The pump 68 serves to suck air from the outside through the air filter 81 , and supply air to the combustor 56 , carbon monoxide remover 55 , and an air pole 58 of the fuel battery 53 . A flow rate of air supplied to the combustor 56 is measured by the flow sensor 70 and controlled by the control valve 69 . A flow rate of air supplied to the carbon monoxide remover 55 is measured by the flow sensor 72 and controlled by the control valve 71 . A flow rate of air supplied to the fuel battery 53 is measured by the flow sensor 73 .
[0088] ON-OFF valve 67 serves to control ceasing and/or starting of an emission flow from the combustor 56 .
[0089] A liquid mixture of fuel liquid and water is supplied to the vaporizing device 1 , and is vaporized in the liquid absorbing member 2 of the vaporizing device 1 . The gas mixture of vaporized liquid fuel and water is further supplied to the reformer 54 . The outlet nipple 6 of high heat conductivity is heated by the heating coil 11 , and the outlet nipple 6 also reaches the reformer 54 . Therefore, the gas mixture of vaporized liquid and water is prevented from returning to a liquid state before being sent to the reformer 54 . Here, since the inlet nipple 5 reaches the reformer 54 and heat is conducted from the reformer 54 to the inlet nipple 5 to heat the other end portion at discharging side of the liquid absorbing member 2 , the heating coil 11 may be omitted.
[0090] In the reformer 54 , the gas mixture of fuel and water supplied from the vaporizing device 1 is reformed into hydrogen in the presence of a catalyst, as shown by the following chemical equations (1) and (2). A gas mixture of products generated at the reformer 54 is supplied to the carbon monoxide remover 55 , and air is also supplied to the carbon monoxide remover 55 from the pump 68 . In the carbon monoxide remover 55 , the carbon monoxide contained in the gas mixture is selectively oxidized in the presence of a catalyst as shown by chemical equation (3). The micro-reactor 52 is provided with a thin film heater 82 made of an electric heating material. The reformer 54 and carbon monoxide remover 55 are heated by the thin film heater 82 .
CH 3 OH+H 2 O→3H 2 +CO 2 (1)
2CH 3 OH+H 2 O→5H 2 +CO+CO 2 (2)
2CO+O 2 →2CO 2 (3)
[0091] The fuel battery 53 is provided with a fuel pole 57 holding catalytic agent particles, air pole 58 holding catalytic agent particles, and a solid polymer electrolyte membrane 59 intervening between the fuel pole 57 and the air pole 58 . The fuel pole 57 is supplied with the gas mixture from the carbon monoxide remover 55 . The air pole 58 is supplied with air from the pump 68 . At the fuel pole 57 , hydrogen contained in the gas mixture is separated into hydrogen ions and electrons by catalytic action of the catalytic agent particles as shown by chemical equation (4). Hydrogen ions are conducted to the oxygen pole 58 through the solid polymer electrolyte membrane 59 , and electrons are taken out from the fuel pole 57 . At the oxygen pole 58 , electrons, oxygen ions, and hydrogen ions react to produce water as shown by chemical equation (5). Consequently, electric energy is generated by the fuel battery 53 . Here, water may be supplied to the fuel pole 57 and oxygen pole 58 from the pump 61 .
H 2 →2H + +2e − (4)
2H + +½O 2 +2e − →H 2 O (5)
[0092] Off-gas, containing hydrogen which did not go under reaction at the fuel pole 57 , is supplied to the combustor 56 . In the combustor 56 , oxygen contained in air supplied from the pump 68 and unreacted hydrogen react in the presence of a catalyst to generate combustion heat. The combustion heat is used to help reaction at the reformer 54 and the carbon monoxide remover 55 . Discharging gas of the combustor 56 is discharged outside through ON-OFF valve 67 .
[0093] FIG. 5 is a block diagram showing power generating device 50 A. In FIG. 5 , elements of the power generating device 50 A that are identical to those of the power generating device 50 shown in FIG. 3 are designated by the same reference numerals.
[0094] In the power generating device 50 A, a pressure sensor 91 is connected to the inlet nipple 5 of the vaporizing device 1 to measure a pressure of the liquid mixture supplied to the inlet nipple of the vaporizing device 1 , and a pressure sensor 92 is provided between the combustor 56 and ON-OFF valve 67 to measure a pressure of the discharging gas from the combustor 56 . The outlet nipple 6 of the vaporizing device 1 and the pressure sensor 92 are connected through the combustor 56 , the fuel pole 57 of the fuel battery 53 , the carbon monoxide remover 55 , and reformer 54 . Therefore, the pressure sensor 92 serves to substantially measure a pressure of the gas mixture discharged from the outlet nipple 6 of the vaporizing device 1 .
[0095] The pressure sensor 91 and pressure sensor 92 each converts displacement of a built-in diaphragm into an electric signal using a voltage element or electrostatic capacity, to detect a pressure.
[0096] The power generating device 50 A is provided with a control circuit to control the pumps 61 and 64 . Being controlled by the control circuit, the pumps 61 and 64 regulate liquid flow rate of water and liquid fuel, thereby regulating the pressure of the liquid mixture to be supplied to the vaporizing device 1 . Here, the control circuit also serves as a control circuit for the vaporizing device 1 . The pumps 61 and 64 serve as supplying section of the vaporizing device 1 , and the pressure sensor 92 serves as measuring section of the vaporizing device 1 .
[0097] Pressure signals measured by the pressure sensor 91 and pressure sensor 92 are fed back to the control circuit. The control circuit regulates pressures of liquid mixtures by the pumps 61 and 64 based on the pressure signals fed back thereto, so that the pressure of the liquid mixture supplied to the vaporizing device 1 becomes equivalent to the pressure of the gas mixture supplied from the vaporizing device 1 to the reformer 54 . Specifically, the control circuit controls the pumps 61 and 64 to reduce liquid flow rate, in case the pressure measured by the pressure sensor 91 is much larger than or exceeds the pressure measured by the pressure sensor 92 . Meanwhile, the control circuit controls the pumps 61 and 64 to increase liquid flow rate, in case the pressure measured by the pressure sensor 91 becomes smaller than the pressure measured by the pressure sensor 92 .
[0098] FIG. 6 is a block diagram of power generating device 50 B. In FIG. 6 , elements of the power generating device 50 B that are identical to those of the power generating device 50 A shown in FIG. 5 are designated by the same reference numerals.
[0099] The power generating device 50 B is provided with control valves 62 B and 65 B in place of ON-OFF valves 62 and 65 .
[0100] The pumps 61 and 64 are not installed on the power generating device 50 B. Instead, air is sent to a water tank and fuel tank provided of the fuel reservoir 51 by the pump 68 through a back-pressure pipe 76 . By controlling the amount of the air being sent, the water is supplied to the vaporizing device 1 from the fuel reservoir 51 through the control valve 62 B, the liquid fuel is supplied to the vaporizing device 1 from the fuel reservoir 51 through the control valve 65 B, and the pressure measured at pressure sensor 91 is controlled. The control valve 62 B serves to regulate the total liquid amount of the water supplied to the vaporizing device 1 , and the control valve 65 B serves to regulate the total liquid amount of liquid fuel supplied to the vaporizing device 1 .
[0101] The control circuit of the power generating device 50 B controls the control valves 62 B and 65 B based on the pressure signals fed back from the pressure sensor 91 and pressure sensor 92 . The control circuit controls the control valves 62 B and 65 B so that the pressure of the liquid mixture supplied to the vaporizing device 1 becomes equivalent to the pressure of the gas mixture supplied to the reformer 54 , or the both pressures to be kept constant. Here, the pressure sensor 92 can be installed between the vaporizing device 1 and the reformer 54 , between the reformer 54 and the carbon monoxide remover 55 , or between the carbon monoxide remover 55 and combustor 56 .
[0102] In a case where control to avoid such difference in pressures is not performed, when at least either of the pressure measured by the pressure sensor 91 or the pressure measured by the pressure sensor 92 changes, extrusion force of the liquid in the liquid absorbing member 2 changes due to the pressure difference caused by such change in pressure. Therefore, the amount of vaporization at the liquid absorbing member 2 was not steady. In addition, a load power, in the opposite direction to a force of pulling liquid under influence of a capillary action in the liquid absorbing member 2 , works in the fuel reservoir 51 and suppresses the force of pulling liquid under influence of a capillary action. Therefore, the amount of vaporization at the liquid absorbing member 2 was not steady.
[0103] In the present embodiment, even in a case where either of the pressure measured by the pressure sensor 91 or the pressure measured by the pressure sensor 92 increases or decreases, or the load power works in the fuel reservoir 51 , pressures at the introduction side and discharging side of the liquid absorbing member 2 are kept constant to balance out such occurrences. Therefore, the amount of vaporization is kept constant by the liquid pulling force under influence of a capillary action. Here, the pressures at the introduction side and discharging side of the liquid absorbing member 2 do not always have to be equivalent, but as long as these pressures are kept constant, the amount of vaporization can be kept constant.
[0104] A relationship between the pressure at the discharging side and the amount of vaporization in the vaporizing device 1 was obtained by experiments. FIG. 7 is a schematic view showing experimental equipment, which is prepared so that a pressure difference occurs, for a comparison purpose. As shown in FIG. 7 , a fuel tank 101 is connected to a mass flow meter 102 through a tube, and the mass flow meter 102 is connected to the inlet nipple 5 of the vaporizing device 1 , and the outlet nipple 6 of the vaporizing device 1 is connected to a flask 103 . Meanwhile, an injector 105 is connected to the flask 103 through a valve 104 , and a pressure gage 106 is connected to the flask 103 . A solution of 60 wt % methanol is poured into the fuel tank 101 , and absorbed by the liquid absorbing member 2 in the vaporizing device 1 under influence of a capillary action. The fuel tank 101 is placed in open air and kept at atmospheric pressure, so the difference between pressure at the discharging side and pressure at the introduction side of the vaporizing device 1 varies as vaporization progresses.
[0105] In this experimental equipment, the pressure at the discharging side of the vaporizing device 1 was regulated with the injector 105 , the pressure was measured with the pressure gage 106 , and a flow rate of methanol solution was measured with the mass flow meter 102 . The results of the measurement are shown in FIG. 8 . As is clear from FIG. 8 , as the pressure at the discharging side of the vaporizing device 1 increases, that is, as the pressure at the discharging side of the vaporizing device 1 exceeds the pressure at the introduction side according to the progress of vaporization, the flow rate of the methanol solution decreases, whereby amount of vaporization of the methanol solution per unit time decreases.
[0106] Meanwhile, in experimental equipment shown in FIG. 9 , the fuel tank 101 is kept airtight. Since the fuel tank 101 is connected to the flask 103 through a tube, the pressure at the discharging side of the vaporizing device 1 is kept equivalent to the pressure at the introduction side. In this experimental equipment, the pressure at the discharging side of the vaporizing device 1 was regulated with the injector 105 , pressure was measured with the pressure gage 106 , and a flow rate of methanol solution was measured with the mass flow meter 102 . The results of the experiment are shown in FIG. 10 . As is clear from FIG. 10 , even in case where the pressure at the discharging side of the vaporizing device 1 changes, the pressure at the discharging side of the vaporizing device 1 is kept equivalent to the pressure at the introduction side, whereby the flow rate of the methanol solution does not change, and amount of vaporization of the methanol solution per unit time is kept constant at a high level.
[0107] In both of the above experiments, the heating coil 11 generates the same amount of heat.
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A vaporizing device which can vaporize fuel stably includes: a liquid absorbing member to allow liquid to move from one end portion to the other end portion of the liquid absorbing member under influence of a capillary action; and a heater to heat a side of the other end portion of the liquid absorbing member to vaporize the liquid.
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BACKGROUND OF THE INVENTION
The present invention relates to a switching device, and more particularly, to an improvement on the switching device for use in an air conditioning device installed in a vehicle, which device is capable of selectively providing an automatic control and a manual control.
A device such as an air conditioning device which requires a mode selection is provided with various switches. For example, in a vehicle, known are manual switches capable of setting predetermined hot or chilled air modes and setting blowing amount of the air blown from an air conditioning device, and an automatic switch which automatically controls such mode and blowing amount.
In FIG. 9, shown is a conventional switching device for use in an air conditioning device which switching device is assembled to an instrumental panel of a vehicle compartment.
In FIG. 9, mode switch group 2 and a fan switch 3 are provided on a plate 1. The mode switch group 2 includes a plurality of depression switch buttons each for setting various hot air or chilled air blowing directions, and the fan switch 3 is of slidable type for setting blowing amount of air. An auto mode switch 2a is provided for automatically controlling air blowing direction upon depression thereof. Further, the fan switch 3 has a knob 3a which is slidably movable. When the knob 3a is slidingly brought to a position "AUTO", air blowing amount is automatically controlled in accordance with changes in various air conditions at internal and external portions of the vehicle compartment.
FIG. 10 shows another example showing a conventional switching device for use in the air conditioning device. According to this device, mode switch group 2 and the blower switch group 4 are both constructed by push-type buttons, and a common auto switch 5 is provided between the switch groups 2 and 4.
With the latter structure, when the air blowing direction and the air blowing amount are to be set by an operator's demand, one of the buttons of mode switch group 2 and one of the buttons of the fan switch group 4 are depressed independent of each other, similar to the first-described conventional device shown in FIG. 9. However, when the blowing direction and the blowing amount of the air are both required to be set in an automatic mode, only the auto switch 5 is depressed to obtain a full-automatic state, to thereby simplify manipulation.
In the conventional device shown in FIG. 9, the fan switch 3 is of slidable type, and therefore, the switch does not occupy large space. However, when the both blowing direction and blowing amount of the air are to be controlled automatically, both switches must be manipulated to be ON independently of each other, and therefore, intricate manipulation is required and such intricacy may degrade vehicle drivability.
Further, since the mode switch group 2 and the blow switch group 4 are both in the form of depression switches independent of one another and these must be aligned in a single array in an identical plane, these groups occupy greater space in the instrumental panel. Therefore, compact switching device may not be obtainable.
Furthermore, according to the lever or button type structure shown in FIGS. 9 and 10, it would be difficult to perform fine control to the air blowing amount with the lever or button and accordingly, it would be impossible to promptly obtain optimum air conditioning state within the vehicle compartment.
The above described drawbacks are also recognized in the household electric equipment and audio equipment those being provided with various manipulation switches for switching and/or selecting various functions in accordance with recent demand in equipment having multi-functions.
SUMMARY OF THE INVENTION
The present invention is accomplished in order to overcome the above-described drawbacks, and therefore, it is an object of this invention to provide a switching mechanism which is capable of providing a desired function only by a single ON operation, and promptly switching toward another function and which is compact in size with producing at low cost yet facilitating fine control to air blowing direction, air blowing amount or any functional matters attendant to air conditioning device installed in a vehicle, household electrical equipments and audio equipments.
In order to attain these and other objects, in accordance with a first aspect of this invention there is provided a switching device comprising;
a depression knob projecting from a plate and disposed depressingly manipulatable;
a depression switch for performing a predetermined switching operation in response to depressing operation of the depression knob;
a rotation/depression knob provided on the plate and disposed rotatable and depressingly operable;
a rotation/depression switch for performing a predetermined switching operation in cooperation with rotation or depressing movement of the rotation/depression knob: and,
a coupling mechanism provided between the depression switch and the rotation/depression switch. The coupling mechanism releases an ON-state locking of one of the switches in response to ON operation of remaining one of the switch.
According to a second aspect of this invention, the coupling mechanism according to the invention is constructed in a link mechanism. The link mechanism is provided between the depression switch and the rotation/depression switch. The link mechanism releases an ON-state locking of the rotation/depression switches in accordance with depressing movement of the depression knob, and the link mechanism permits the depression switch to be restored to OFF state in accordance with rotation or depression of the rotation/depression knob.
According to a third aspect of this invention, the depression knob corresponding to that of the first aspect of this invention is provided with a shaft portion whose side wall is formed with a locking step, and the rotation/ depression knob corresponding to that of the first aspect of this invention is provided with a shaft portion whose outer peripheral portion has a conical shape and provided with gear teeth. Further, the association mechanism includes a coupling plate member slidably disposed between the depression knob and the rotation/depression knob. The coupling plate has one end provided with a pawl or cam portion which is engageable with the gear teeth portion of the shaft of the rotation/depression knob, and having another end formed with a looking portion engageable with the locking step of the shaft portion of the depression knob.
According to a fourth aspect of this invention, the coupling mechanism corresponding to the first aspect of this invention includes a release switch which provides OFF state with respect to the depression switch upon ON operation of the release switch; a central shaft connected to the rotation/depression switch knob; and, a release plate having one end fixed to the central shaft and another end provided abutable with the release switch for transmitting depressing movement of the rotation/depression switch knob and turning ON the release switch.
In accordance with the first aspect of this invention, since the depression switch and the rotation/depression switch are interconnected by means of the coupling mechanism, when one of the knobs is turned ON, the remaining knob is automatically turned OFF.
Further, in accordance with the second aspect of this invention, for setting one desirable function, only the depression knob is to be depressed. If another function is intended, the rotation/depression knob is depressed or rotated.
Take an air conditioning device installed in a vehicle for instance, the depression knob for automatic control is only manipulated in order to obtain full automatic state. That is, the depression knob for the automatic control is connected to two automatic switches, and one of the switches is cooperated with a manual switch by means of the link mechanism. Upon depressing movement of the automatic control depression knob, this depression movement is simultaneously transmitted to the manual control switch through the link mechanism, so that a contact of the manual switch is released.
Therefore, for providing the full-automatic state, it is unnecessary to manipulate the manual control knob. In other words, ON operation with respect to the automatic switch and OFF operation with respect to the manual switch are simultaneously performable only by the depressing operation with respect to the depression knob for the automatic control.
When, the switching from the full-automatic state to the manual control state is intended, a contact of the manual control switch is released by rotating or depressing the manual control knob, and at the same time, the movement of the manual control knob is transmitted to the automatic control switch through the link mechanism, so that the automatic control switch is restored to its OFF position.
Further, in accordance with the third aspect of this invention, the depression knob and the rotation/depression knob are directly cooperable by means of the coupling plate. Therefore, synchronous ON/OFF operations relative to the pair of switches are attainable with such simple construction in highly accurate manner.
That is, upon rotation or depression of the rotation/depression knob, the pawl or cam portion of the coupling plate, which pawl or cam has been engaged with the conical gear provided at the outer peripheral surface of the shaft of the rotation/depression knob, will be pushed away by the ridge portion of the gear or by the conically stanting surface thereof. As a result, the locking step formed at the depression knob is moved away from the locking portion of the coupling plate, to thereby restore OFF position. This embodiment requires reduced numbers of mechanical components for interconnecting the knobs, and reliable coupling movement is achievable.
Furthermore, in accordance with the fourth aspect of this invention, when the rotation/depression knob is depressed, the release plate fixed to the central shaft connected to this knob is displaced concurrent with the depressing movement of the depression knob. And the tip end portion of the release plate is brought into abutment with the release switch, so that the release switch is turned ON.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings;
FIGS. 1 and 2 are cross-sectional views showing a switching device according to this invention which is applied to an air conditioning device installed in a vehicle;
FIG. 3 is an enlarged view showing a manual control switch shown in FIGS. 1 and 2;
FIGS. 4A and 4B are views for description of the manual control switch according to the present invention:
FIGS. 5A, 5B and 5C are views for description of a spring for use in the manual control switch according to this invention;
FIGS. 6A, 6B and 6C are views showing a structure of a switching device according to a second embodiment of this invention;
FIGS. 7A-1, 7A-2, 7B, 7C-1, 7C-2, 8A, 8B and 8C are views for description of operation with respect to the device shown in FIG. 6;
FIGS. 9 and 10 are views showing external appearances in conventional switching devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments according to the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view showing a principle structure of a switching device according to this invention.
In FIG. 1, a plate 10 is provided with a depression knob 12 for automatic control and a rotation/depression knob 14 for manual control, these knobs being protrudingly disposed from the plate and spaced away from each other.
Below the automatic control depression knob 12, there are provided a projecting portion 12a and a pawl portion 12b integral therewith and projecting downwardly. The projecting portion 12a and the pawl portion 12b are adapted to directly depress movable portions 18a and 20a, respectively, of an auto mode switch 18 and an auto blow switch 20, respectively.
On the other hand, a sleeve portion 14a is provided at a central portion of the manual control rotation/depression knob 14, and a shaft 24 is in fitting engagement with an inner peripheral surface of the sleeve portion 14a. The shaft 24 is provided with a rotor 28 rotatable together with the rotation of the shaft 24, and is integrally provided with a gear 25 whose conical portion is engraved with gear teeth. These are accommodated within a switch case 30 for the manual control.
Within the manual control switch case 30, a support portion 34 extends from a lower surface of a retainer 32 disposed below the rotor 28. The support portion 34 has an axis 34a about which a switching rod 36 is pivotably provided.
The bottom surface of the rotor 28 and the top surface of the retainer 32 are provided with movable contacts and stable contacts, respectively. When automatic state of the auto blower switch 20 is released, (that is, when the switch becomes its manual operational state), these contacts are in contact with each other upon rotation of the manual control rotation/depression knob 14, to thereby vary the air blowing amount.
Further, a locking piece 38 is pivotally connected to the retainer 32. The locking piece 38 is engageable with the gear 25, and is adapted to hold the switching rod 36 at a given fixed position. The locking piece 38 is normally urged in a clockwise direction by a biasing force of a spring 39.
The retainer 32 has a sub retainer 40 which defines a bottom wall of the case, and a receiving portion 44 for receiving the manual switch plate 42 and a contact thereof is fixedly mounted on an upper surface of the sub retainer 40. Further, a plate 46 is provided which is directed downwardly from the retainer 32 for contacting with the contact of the manual control switch plate 42.
Between the shaft 24 and the rotor 28, a coil spring 48 is interposed. The coil spring 48 urges the shaft 24 toward a direction to restore its original position when the manual control rotation/depression switch knob 14 is depressed to forcibly move the shaft 24 downwardly.
One feature of this invention resides in a provision of a link mechanism which transmits switch movement upon operation of one of the auto switch and the manual switch from one side the other. When one of the switches is turned ON, this movement is transmitted to the remaining switch by way of the link mechanism, so that the latter is controlled to be OFF. As a result, only by a single operation of one of the switches, one of the switches is turned ON, and remaining switch is concurrently turned OFF.
FIG. 3 is an enlarged view showing the manual control switch plate 42 shown in FIGS. 1 and 2. The manual control switch plate 42 includes a mounting member 42a fixed to the sub retainer 40 at the bottom of the manual switch case 30, a biasing member 42b fixed to the mounting member 42a, and a swinging member 42d connected to the mounting and biasing members 42a and 42b and having an end portion provided with contacts 42c 1 and 42c 2 .
A spring member 42e is latched between the mounting member 42a and the swinging member 42d. These members 42a thru 42e in the manual control switch plate 42 is formed of resilient material, and are freely movable except a lower surface of the mounting member 42a, which lower surface is fixed to the sub retainer 40. By an operation described later, the contact 42c of the switch plate 42 is coming into contact with a contact 46a of a plate 46 or the receiving portion 44 upon abutment of the switching rod 36 with an upper end of the biasing member 42b. The plate 46 is in contact with contacts of the retainer 32.
Function attendant to the first embodiment will next be described.
FIG. 1 shows the manual control state in which the manual control rotation/depression knob 14 is turned ON, and FIG. 4 shows an enlarged view showing the manual control switch plate 42 and its ambient portion.
In this ON state of the manual control switch plate 42, the spring member 42e is imparted with a biasing force P 3 , so that horizontal force P 2 and vertical force P 1 are applied with respect to the swinging member 42d, to thereby maintain the geometrical position shown in FIG. 1.
When the automatic control depression knob 12 is depressed, the projecting portion 12a and the pawl portion 12b those provided integral with the knob 12 respectively urge the movable portions 18a and 20a of the auto mode switch 18 and the auto blower switch 20 to provide ON state, so that the two auto switches are simultaneously turned ON by the single switching operation.
In this instance, left end portion of the first link 50 mounted on the movable portion 20a of the auto blower switch 20 is simultaneously moved downwardly, so that the first link 50 is moved in counterclockwise direction about the axis 50a. Therefore, a second link 52 connected to the right end portion of the first link 50 is moved upwardly.
Therefore, the left end portion of the switching rod 36 connected to the lower end portion of the second link 52 is moved upwardly, and the right end portion of the rod 36 is moved downwardly. By the downward movement of the right end portion of the rod 36, the lower surface of the right end portion of the switching rod 36 is brought into abutment with the upper end portion of the swinging member 42d of the manual control switch plate 42 fixedly mounted on the sub retainer 40. As a result, the swinging member 42d is depressed downwardly. With this movement, the biasing direction of the spring 42e interposed between the swinging member 42d and the mounting member 42a of the manual control switch plate 42 is changed. Accordingly, the contact 42c which has been in abutment with the plate 46 will subjected to force to a direction in which the contact 42c will be in abutment, with the receiving portion 44 fixedly mounted on the sub retainer 40.
In a state shown in FIGS. 1, 4(A) and 5(A), the biasing direction of the spring member 42e can be maintained unchanged so long as an operational point C of the spring member 42e is lower side from the line connecting the end point A of the swinging member 42d and other end of the member 42d through the root point B of the spring member 42e.
When the movement of the switching rod 36 in the clockwise direction is further progressed for further moving the biasing member 42b downwardly, the linethrough points A, B and D are displaced to lower from the point C as shown in FIG. 5(B), the force P 1 which has been directed upwardly in vertical direction will be converted into a force P 4 directed downwardly in vertical direction as shown in FIG. 5(C). Therefore, the swinging member 42d is moved in counterclockwise direction, so that the contact 42c 2 provided at the tip end portion thereof is brought into abutment with the receiving portion 44.
Thus, the contact of the manual control switch plate 42 is released to provide OFF state.
Therefore, according to the present invention, both the automatic mode switch 18 and the auto blower switch 20 are simultaneously controlled to be ON upon depression of the automatic control depression knob 12, and at the same time, the manual control switch plate 42 which has been maintained in ON state will be controlled to be OFF.
Next, described below is the switching or change over function from full automatic state to the manual control state.
In the present invention, the manual control rotation/depression knob 14 is in a form of a dial type switch knob which is rotatably provided. The knob is also depressingly operable, so that the switching operation from full automatic state to the manual control state can be made by either one of the rotation and depression of the manual control rotation/depression knob. For shifting the full automatic state to the manual control state, when rotating the manual control rotation/depression knob 14, the gear 25 fixed to the tip end portion of the shaft 28 fitted with the knob 14 is also rotated. In this case, the locking piece 38 is moved in counterclockwise direction by the biasing force of the spring 39 with the locking piece 38 being clickingly slidable on a conically slanting surface of the gear teeth portion, so that the locking piece 38 is disengaged from the gear 25. Simultaneously, the switching rod 36 is disengaged from the locking piece 38, and the right end portion of the switching rod 36 is urged upwardly by the biasing force accumulated in the manual control switch plate 42, and is moved in counterclockwise direction.
In this case, the contact 42c 1 of the manual control switch is in abutment with the projecting portion 46a of the plate 46, so that manual operation mechanism is attainable.
Concurrently, the second link 52 connected to the switching rod 36 is moved downwardly by the downward pivotal movement of the left end portion of the switching rod 36. Further, the left end portion of the first link 50 connected to the second link 52 is pivotally moved upwardly about the axis 50a. With this movement, the pawl portion 12b of the automatic control depression knob 12 is urged upwardly to thereby restore original position of the auto mode switch 18 and the auto blower switch 20.
As described above, the manual control rotation/depression knob 14 is provided depressingly operable in accordance with the present invention. Therefore, shifting from the full-automatic state to the manual control state can also be made by the depressing operation of the knob 14. In the latter case, when the manual control rotation/depression knob 14 is depressed against the biasing force of the coil spring 48, the gear 25 provided at the tip end, of the shaft 24 is moved downwardly, so that the switching rod 36 is disengaged from the gear 25, to thereby pivotally move the switching rod 36 in counterclockwise direction by the biasing force of the manual control switch plate 42. Thereafter, shifting to the manual control is effected in the manner similar to that in the rotational operation of the knob 14.
Next, another embodiment according to the present invention will be described with respect to FIGS. 6A thru 8C. Central feature in the second embodiment resides in approximately direct connection between the both switch knobs with reduced numbers of mechanical components by means of a cam locking mechanism which makes use of a slant surface, ridge portions and valley portions of a conical gear.
Similar to the first embodiment, the second embodiment exhibits an effect similar to that attainable in the first embodiment. When one of the switch knobs is turned ON, the remaining switch knob is simultaneously and automatically turned OFF.
FIG. 6(A) is a front view showing a switching device according to the second embodiment. FIG. 6(B) is a cross-sectional view taken along the line 6B--6B in FIG. 6(A), and FIG. 6(C) is a cross-sectional view taken along the line 6C--6C of FIG. 6(B). In these drawings, a depression switch 60 having a protruding depression knob 60a and a rotation/depression switch 62 having a rotation/depression switch knob 62a which is provided rotatable and depressingly operable are assembled on a plate 64 formed of a printing board.
The rotation/depression switch knob 62a is integrally provided with a shaft 62b which is accommodated within a rotation/depression switch case 62c. A spring 62d is disposed over an outer peripheral surface of the shaft 62b, so that the shaft is urged upwardly in FIG. 6(B).
As is apparent from FIG. 6(C), the shaft has an outer peripheral portion formed with a gear teeth, and a spring 62f is fixedly embedded at a side wall, so that a ball 62e is urged toward an inner peripheral surface of the case 62c. On the other hand, at the lower end of the depression switch knob 60a, a locking plate 60b is urged rightwardly in the drawing by a biasing force of a locking spring 60c.
The locking plate 60b has a tip end fixed with a cam 62g which extends through the case 62c of the rotation/depression switch 62 and is engageable with the gear of the shaft 62b. As will be described later, the combination of the locking plate 60b, the locking spring 60c, the cam 62g and the gear at the outer peripheral surface of the shaft 62b serves as coupling mechanism between the switches 60 and 62.
In this embodiment, by a single depressing operation to the depression switch 60, automatic control mode is provided with respect to both air blowing direction and air blowing amount. On the other hand, by the rotation or depressing operation of the rotation/depression switch 62, the automatic control mode will be converted into a manual control mode. Also, in this embodiment, the depression switch 60 and the rotation/depression switch 62 are mutually associated with each other in terms of ON/OFF operations. That is, upon ON/OFF operation to the one of the switches 60 and 62, the remaining one of the switches 62 and 60 is simultaneously controlled to be OFF/ON, so that in the air conditioning device switching operation between automatic control and manual control can be effected by a single operation. Further, since the rotation/depression switch 62 which is the manual control switch controls the air blowing amount by the rotation of the knob 62, fine control to the air blowing amount is facilitated and optimum air conditioning state is promptly obtainable, which fine control has been troublesome by the conventional depression type or slide lever type switch.
Further, in the second embodiment, as is apparent from the drawings the coupling mechanism between the depression switch 60 and the rotation/depression switch 62 is of simple structure requiring minimized numbers of mechanical components. Therefore, high productivity and assemblability result, to thereby lower production cost.
Next, operation mode according to the second embodiment will be described.
Shown in FIG. 7(A1), 7(A2), 7B, 7(C1) and 7(C2) is a schematic illustration showing an essential portion of the association mechanism between the depression switch 60 and the rotation/depression switch 62. Further, the operational relationship between the depression switch knob 6Oa and the locking plate 60b is shown in FIGS. 8A-8C. FIGS. 7(A1) and 7(A2) show the interconnection between the switches 60 and 62 when the air conditioning device is settled in the automatic control mode by the depression to the depression switch 60.
When the depression switch knob 60a is depressedly moved from a position shown by a chain line to a solid line in FIG. 7(A2), the locking plate 60b is pushedly moved rightwardly in the drawing against the biasing force of the locking spring 60c. As a result, the cam 62g connected to the locking plate 60b is brought into engagement with the gear provided at the outer peripheral surface of the shaft 62b of the rotation/depression switch 62.
In this case, starting from the state shown in FIG. 8(A), when he depression switch knob 60a is completely depressed, a locking notch 60a1 formed at a side portion of the switch knob 60a is brought into engagement with a recessed portion 60b1 formed at the locking plate 60b as shown in FIG. 8(B). As a result, lateral position of the locking plate 60b is held unchanged by a biasing force of a spring (not shown) which urges the depression switch knob 60a upwardly in FIG. 8(B). Accordingly, the cam 62g is maintainingly engaged with the valley portion of the gear of the shaft 62b. Thus, the automatic control mode is established, so that air blowing amount and air blowing direction are optimumly automatically controlled in accordance with conditions inside and outside the vehicle compartment.
Starting from the automatic control state, when the rotation/depression switch knob 62a is depressed or rotated as shown in FIGS. 7(B), 7(C1) and 7(C2), the cam 62g shown in FIG. 7(A1) and 7(A2) is disengaged from the gear of the shaft 62b, so that the locking plate 60b is slidingly moved leftwardly to restore its original position. At the same time, the depression switch knob 60a is returned to a position shown by the chain line, to thereby release automatic control state and provide the manual control mode.
That is, as shown in FIG. 7(B), when the rotation/depression switch knob 62 is depressed, the shaft 62b is moved downwardly so that the cam 62g is pushedly moved leftwardly as indicated by an arrow, since the gear provided at the outer peripheral surface of the shaft 62b is in a form of an inverted frusto-conical shape. Therefore, the tip end of the cam 62g is spaced away from the gear to disengage therefrom.
Simultaneously, the locking plate 60b is moved leftwardly in FIG. 8(C), so that the recessed portion 60b of the locking plate 60b is disengaged from the notched portion 60a1 of the depression switch knob 60a. Accordingly, the depression switch knob 60a is moved upwardly because of the biasing force of the spring (not shown), to thereby release automatic control state. With such operation, interconnection between the depression switch 60 and the rotation/depression switch 62 is released by the leftward movement of the cam 62g. Therefore, the rotation/depression switch knob 62a restores its original position by the biasing force of the spring 62d, so that the rotation/depression switch knob can undergo manual rotation control.
FIGS. 7(C1) and 7(C2) shows another operation in which the automatic control mode is converted into the manual control mode not by the depression to the rotation/depression switch knob 62a but by rotating the same. When the rotation/depression switch knob 62a is rotated to either one direction, the shaft 62b is also rotated about its axis, so that positional relationship relative to the cam 62g which has been fixedly positioned and associated with the depression switch 60 is changed. As a result, the tip end of the cam 62g which has been fitted with the valley portion of the shaft 62b will ride over the ridge portion of the gear. By this riding over operation of the cam, the cam 62g together with the locking plate 62b are pushed leftwardly in the drawing, and the cam is disengaged from the gear similar to the above-described depressing operation. As a result, the depression switch knob 60a moves upwardly to restore its original position.
As described above, according to the second embodiment of this invention, the depression switch knob 60a is automatically controlled into reversed state by the manipulation of the rotation/depression switch knob 62a. Substantial mechanical association between these switches 60 and 62 can be stabilizingly provided by the minimized numbers of the mechanical components such as the locking plate 60b, the locking spring 60c and the cam 62g. Therefore, switching operation between the automatic control and the manual control can be effected with simple construction and high reliability.
The above description concerns a case where the present invention is applied to the air conditioning device installed in the vehicle compartment. However, the present invention is not limited to this case, but the invention is also available to the household electrical equipments and audio equipment.
As described above, according to the present invention, the switches having functions different from each other are cooperably movable by means of the link mechanism, and ON operation to one of the switches simultaneously provides OFF state with respect to the remaining switch. Therefore, prompt and stabilized switching operation is attainable only by the mechanical associating mechanism having simple construction.
Further, since one of the switches is in the form of the dial type switch which is rotatable and depressable, the component on the instrument panel does not occupy great space, to thereby render the switching device compact in terms of spacial efficiency.
Furthermore, since one pair of the switch knobs are cooperably movable by means of the coupling plate only, stable cooperational movement is attainable with a reduced numbers of the mechanical components.
Moreover, since the rotation/depression switch knob also serves as the air blowing amount controlling knob, stabilized operability is attainable, and fine control is facilitated by controlling the knob.
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A switching device is disclosed in which a depression switch and a rotation/depression switch are interconnected by means of a coupling mechanism. When one of the knobs is turned ON, the remaining knob is automatically turned OFF. The switching device includes a depression knob projecting from a plate and disposed depressingly manipulatable; the depression switch for performing a predetermined switching operation in response to depressing operation of the depression knob; a rotation/depression knob provided on the plate and disposed rotatable and depressingly operable; the rotation/depression switch for performing a predetermined switching operation in cooperation with rotation or depressing movement of the rotation/depression knob; and, a coupling mechanism provided between the depression switch and the rotation/depression switch. The coupling mechanism releases a contact of one of the switches in response to ON operation of remaining one of the switch.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an organic light emitting device constituted by an anode, an organic compound film capable of emitting light under the action of an electric field, and a cathode. In particular, the present invention relates to an organic light emitting device using a light emitting material which emits light in a triplet exited state.
[0003] 2. Description of the Related Art
[0004] An organic light emitting device is a device designed by utilizing a phenomenon in which electrons and holes are caused to flow into an organic compound film through two electrodes by application of a voltage to cause emission of light from molecules in an excited state (excited molecules) formed by recombination of the electrons and holes.
[0005] Emission of light from an organic compound is a conversion into light of energy released when excited molecules are formed and then deactivated into the ground state. Deactivation processes causing such emission of light are broadly divided into two kinds: a process in which deactivation proceeds via a state in which excited molecules are singlet excited molecules (in which fluorescence is caused), and a process in which excited molecules are triplet excited molecules. Deactivation processes via the triplet excited molecule state include an emission process in which phosphorescence is caused and a triplet-triplet extinction process. However, there are basically only a small number of organic materials capable of changing in accordance with the phosphorescent deactivation process at room temperature. (In ordinary cases, thermal deactivation different from deactivation with emission of light occurs.) The majority of organic compounds used in organic light emitting devices are materials which emit light by fluorescence via the singlet excited molecule state, and many organic light emitting devices use fluorescence.
[0006] Organic light emitting devices using such organic compounds capable of emitting light by fluorescence are based on the two-layer structure which was reported by C. W. Tang et al. in 1987 (Reference 1: C. W. Tang and S. A. Vanslyke, “Organic electroluminescent diodes”, Applied Physics Letters, Vol. 51, No. 12, 913-915 (1987)), and in which an organic compound film formed of layers of two or more organic compounds and having a total thickness of about 100 nm is interposed between electrodes. Adachi et al. thereafter proposed a three-layer structure in 1988 (Reference 2: Chihaya ADACHI, Shozuo TOKITO, Tetsuo TSUTSUI and Shogo SAITO, “Electroluminescence in Organic Films with Three-Layered Structure”, Japanese Journal of Applied Physics, Vol. 27, No. 2, L269-L271 (1988)). Multilayer device structures based on applications of these layered structures are being presently used.
[0007] Devices in such multilayer structures are characterized by “layer function separation”, which refers to the method of separately assigning functions to layers, instead of making one organic compound have various functions. For example, a device of two-layer structure uses a hole transporting layer having the function of transporting positive holes, and a light emitting and electron transporting layer having the function of transporting electrons and the function of emitting light. Also, a device of three-layer structure uses a hole transporting layer having only the function of transporting positive holes, an electron transporting layer having only the function of transporting electrons, and a light-emitting layer which is capable of emitting light, and which is formed between the two transporting layers. Such a layer function separation method has the advantage of increasing the degree of molecular design freedom of organic compounds used in an organic light emitting device.
[0008] For example, a number of characteristics, such as improved facility with which either of electrons and holes are injected, the function of transporting both the carriers, and high fluorescent quantum yield, are required of a device of single-layer structure. In contrast, in the case of a device of two-layer structure or the like using an electron transporting and light emitting layer, an organic compound to which positive holes can be easily injected may be used as a material for a hole transporting layer, and an organic compound to which electrons can be easily injected and which have high fluorescent quantum yield may be used as a material for an electron transporting layer. Thus, requirements of one layer are reduced and the facility with which the material is selected is improved.
[0009] In the case of a device of three-layer structure, a “light emitting layer” is further provided to enable separation between the electron transporting function and the light emitting function. Moreover, a material in which a fluorescent pigment (guest) of high quantum yield such as a laser pigment is dispersed in a solid medium (host) material can be used for the light emitting layer to improve the fluorescent quantum yield of the light emitting layer. Thus, not only the effect of largely improving the quantum yield of the organic light emitting device but also the effect of freely controlling the emission wavelength through the selection of fluorescent pigments to be used can be obtained (Reference 3: C. W. Tang, S. A. Vanslyke and C. H. Chen, “Electroluminescence of doped organic thin films”, Journal of Applied Physics, Vol. 65, 3610-3616 (1989)). A device in which such a pigment (guest) is dispersed in a host material is called a doped device.
[0010] Another advantage of the multilayer structure is a “carrier confinement effect”. For example, in the case of the two-layer, structure described in Reference 1, positive holes are injected from the anode into the hole transporting layer, electrons are injected from the cathode into the electron transporting layer, and the holes and electrons move toward the interface between the hole transporting layer and the electron transporting layer. Thereafter, while holes are injected into the electron transporting layer because of a small ionization potential difference between the hole transporting layer and the electron transporting layer, electrons are blocked by the hole transporting layer to be confined in the electron transporting layer without being injected into the hole transporting layer because the electrical affinity of the hole transporting layer is low and because the difference between the electrical affinities of the hole transporting layer and the electron transporting layer is excessively large. Consequently, both the density of holes and the density of electrons in the electron transporting layer are increased to achieve efficient carrier recombination.
[0011] As an example of a material that is effective in exhibiting the carrier confinement effect, there is a material having an extremely large ionization potential. It is difficult to inject holes into the material having a large ionization potential, so that such a material is widely used as a material capable of blocking holes (hole blocking material). For example, in the case where the hole transporting layer composed of an aromatic diamine compound and the electron transporting layer composed of tris(8-quinolinolato)-aluminum (hereinafter referred to as “Alq”) are laminated as reported in Reference 1, if a voltage is applied to the device, Alq in the electron transporting layer emits light. However, by inserting the hole blocking material between the two layers of the device, holes are confined in the hole transporting layer, so that light can be emitted from the hole transporting layer side as well.
[0012] As described above, layers having various functions (hole transporting layer, hole blocking layer, electron transporting layer, electron injection layer, etc.) are provided to improve the efficiency and to enable control of the color of emitted light, etc. Thus, multilayer structures have been established as the basic structure for current organic light emitting devices.
[0013] Under the above-described circumstances, in 1998, S. R. Forrest et al. made public a doped device in which a triplet light emitting material capable of emission of light (phosphorescence) from a triplet excited state at a room temperature (a metal complex having platinum as a central metal in the example described in the reference) is used as a guest (hereinafter referred to as “triplet light emitting device) (Reference 4: M. A. Baldo, D. F. O'Brien, Y You, A. Shoustilkov, S. Silbley, M. A. Thomoson and S. R. Forrest, “Highly efficient phosphorescent emission from organic electroluminescent devices”, Nature, Vol. 395, 151-154 (1998)). For distinction between this triplet light emitting device and devices using emission of light from a singlet excited state, the latter device will be referred to as “singlet light emitting device”.
[0014] As mentioned above, excited molecules produced by recombination of holes and electrons injected into an organic compound include singlet excited molecules and triplet excited molecules. In such a case, singlet excited molecules and triplet excited molecules are produced in proportions of 1:3 due to the difference between the multiplicities of spin. Basically, in the existing materials, triplet excited molecules are thermally deactivated at room temperature. Therefore only singlet excited molecules have been used for emission of light, only a quarter of produced excited molecules are used for emission of light. If triplet excited molecules can be used for emission of light, a light emission efficiency three to four times higher than that presently achieved can be obtained:
[0015] In Reference 4, the above-described multilayer structure is used. That is, the device is such structured that: 4,4′-bis[N-(1-naphthyl)-N-phenyl-amino]-biphenyl (hereinafter referred to as “α-NPD”) that is an aromatic amine-based compound, is used as the hole transporting layer; Alq with 6% of 2,3,7,8,12,13,17,18-octaethyl-21H,23H-porphyrin-platinum (hereinafter referred to as “PtOEP”) dispersed therein is used as the light emitting layer; and Alq is used as the electron transporting layer. As to the external quantum efficiency, the maximum value is 4% and a value of 1.3% is obtained at 100 cd/m 2 .
[0016] Thereafter, the device structure utilizing the hole blocking layer is used. That is, the device is such structured that: α-NPD is used as the hole transporting layer; 4,4′-N,N′-dicarbazole-biphenyl (hereinafter referred to as “CBP”) with 6% of PtOEP dispersed therein is used as the light emitting layer; 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (hereinafter referred to as “BCP”) is used as the hole blocking layer; and Alq is used as the electron transporting layer. As to the external quantum efficiency, a value of 2.2% is obtained at 100 cd/m 2 and the maximum value is 5.6%, so that the light emission efficiency of the device is improved (Reference 5: D. F O'Brien, M. A. Baldo, M. E. Thompson and S. R. Forrest, “Improved energy transfer in electrophosphorescent devices”, Applied Physics Letters, Vol. 74, No. 3, 442-444 (1999)).
[0017] Further, a triplet light emitting device is reported which uses tris(2-phenylpyridine)iridium (hereinafter referred to as “Ir(ppy) 3 ”) as the triplet light emitting material (Reference 6: M. A. Baldo, S. Lamansky, P. E. Burrows, M. E. Thompson and S. R. Forrest, “Very high-efficiency green organic light-emitting devices based on electrophosphorescence”, Applied Physics Letters, Vol. 75, No. 1, 4-6 (1999)). Thereafter, it is reported that with the same device structure as in Reference 6, the film thicknesses of the organic compound films are optimized, whereby a highly efficient organic light emitting device is obtained whose external quantum efficiency is 14.9% at 100 cd/m 2 (Reference 7: Teruichi Watanabe, Kenji Nakamura, Shin Kawami, Yoshinori Fukuda, Taishi Tsuji, Takeo Wakimoto, Satoshi Miyaguchi, Masayuki Yahiro, Moon-Jae Yang, Tetsuo Tsutsui, “Optimization of emitting efficiency in organic LED cells using Ir complex”, Synthetic Metals, Vol. 122, 203-207 (2001)). Thus, in actuality, it becomes possible to produce the devices with the light emission efficiency almost three times that in the conventional singlet light emitting device.
[0018] Searches are presently being made for triplet light emitting materials using iridium or platinum as a central metal, triplet light emitting devices having markedly high efficiency in comparison with singlet light emitting devices are now attracting attention, and studies about such devices are being energetically made.
[0019] Although triplet light emitting devices have light emission efficiency much higher than that of singlet light emitting devices, they are incomparably shorter in life than singlet light emitting materials and lack stability. Also, a multilayer structure adopted to increase the efficiency of a triplet light emitting device must be formed so as to have at least four layers. Therefore triplet light emitting devices simply have the drawback of requiring much time and labor for fabrication.
[0020] With respect to the life of devices, a report has been made which says that the half-life of a device having a multilayer structure formed of a hole transporting layer using α-NPD, a light emitting layer using CBP as a host material and Ir(ppy) 3 as a guest (dopant) material, a hole blocking layer using BCP, and an electron transporting layer using Alq is only 170 hours under a condition of an initial luminance of 500 cd/m 2 (Reference 8: Tetsuo TSUTSUI, Moon-Jae YANG, Masayuki YAHIRO, Kenji NAKAMURA, Teruichi WATANABE, Taishi TSUJI, Yoshinori FUKUDA, Takeo WAKIMOTO and Satoshi MIYAGUCHI, “High Quantum Efficiency Inorganic Light-Emitting Devices with Iridium-Complex as a Triplet Emissive Center”, Japanese Journal of Applied Physics, Vol. 38, No. 12B, L1502-L1504 (1999)). By considering this life, it must be said that no solution of the life problem is close at hand.
[0021] In Reference 8, low stability of BCP used as a hole blocking material is mentioned as a cause of the limitation of life. Triplet light emitting devices use as a basic structure the device structure described in Reference 5, and use the hole blocking layer as an indispensable element. FIG. 12 show the structure of a conventional triplet light emitting device. In the device structure shown in FIG. 12 , an anode 1102 is formed on a substrate 1101 , a multilayer organic compound film formed of a hole transporting layer 1103 , a light emitting layer 1104 , a hole blocking layer 1105 , and an electron transporting layer 1106 is formed on the anode 1102 , and a cathode 1107 is formed on the multilayer film. While efficient carrier recombination can be achieved by the carrier confinement effect of the hole blocking layer, the life of the device is limited because the hole blocking material ordinarily used is considerably low in stability. Also, CBP used as a host material is also low in stability and is also considered to be a cause of the limitation of the life.
[0022] A device of three-layer structure using no hole blocking layer has been fabricated (Reference 9: Chihaya ADACHI, Marc A. Baldo, Stephen R. Forrest and Mark E. Thompson, “High-efficiency organic electrophosphorescent devices with tris(2-phinylpyridine) iridium doped into electron-transporting materials”, Applied Physics Letters, Vol. 77, No. 6, 904-906 (2000)). This device is characterized by using electron transporting materials as a host material instead of CBP which is the to have such characteristics as to transport both the carriers. However, the electron transporting materials used as a host material are BCP which is used as a hole blocking material, 1,3-bis(N,N-t-butyl-phenyl)-1,3,4-oxazole (hereinafter referred to as “OXD7”), and 3-phenyl-4-(1′-naphthyl)-5-phenyl-1,2,4-triazole (hereinafter referred to as “TAZ”). Although no hole blocking layer is used, the materials ordinarily used as a hole blocking material are used in the device. BCP is, of course, lower in stability than any other material, so that the stability of the device is low, while the efficiency is high.
[0023] A simple two-layer device structure using no hole blocking material has also been reported (Reference 10: Chihaya ADACHI, Raymond KWONG, Stephen R. Forrest, “Efficient electrophosphorescence using a doped ambipolar conductive molecular organic thin film”, Organic Electronics, Vol. 2, 37-43 (2001)). In this device, however, CBP is used as a host material, so that the stability is low, while the light emission efficiency is high.
[0024] As described above, while triplet light emitting devices having high light emission efficiency have been reported, no triplet light emitting device improved both in efficiency and in stability has been reported. Difficulty in obtaining such an improved device is due to the instability of host materials and hole blocking materials used.
SUMMARY OF THE INVENTION
[0025] An object of the present invention is to provide a triplet light emitting device in which unstable materials such as those described above are not used while the device structure is simplified to obtain high efficiency and improved stability, and which can be fabricated easily and efficiently in comparison with the conventional devices.
[0026] According to the present invention, a triplet light emitting device designed to achieve the above-described object has a simple device structure ( FIG. 1 ) in which no hole blocking layer such as that provided in the conventional triplet light emitting devices is used, and in which an organic compound film is formed as a multilayer film constituted by a hole transporting layer and a layer in which dopant material capable of triplet light emission is dispersed in a stable electron transporting material. That is, a device structure is provided in which an anode 102 is formed on a substrate 101 , a hole transporting layer 103 constituted by a hole transporting material, an electron transporting and light emitting layer 104 constituted by an electron transporting material and a dopant material capable of triplet light emission are successively formed on the anode 102 , and a cathode 105 is formed on the layer 104 . The region interposed between the anode 102 and the cathode 105 (i.e., the hole transporting layer 103 and the electron transporting and light emitting layer 104 ) corresponds to the organic compound film.
[0027] The present invention is characterized in that, in an organic light emitting device constituted by an anode, an organic compound film, and a cathode, the organic compound film includes a hole transporting layer constituted by a hole transporting material, and an electron transporting layer formed adjacent to the hole transporting layer and constituted by an electron transporting material, and a light emitting material capable of emitting light from a triplet excited state is added in the electron transporting layer.
[0028] A hole injection layer may be inserted between the anode 102 and the hole transporting layer 103 . Also, an electron injection layer may be inserted between the cathode 105 and the electron transporting and light emitting layer 104 . Further, both the hole injection layer and the electron injection layer may be inserted.
[0029] As a means for achieving the object of the present invention, it is important to consider the combination of a hole transporting material and an electron transporting material in the above-described device for preventing emission of light from the hole transporting layer 103 .
[0030] Accordingly, the present invention is characterized in that the energy difference between the highest occupied molecular orbit level and the lowest unoccupied molecular orbit level in the hole transporting material is larger than the energy difference between the highest occupied molecular orbit level and the lowest unoccupied molecular orbit level in the electron transporting material.
[0031] Another means for achieving the object resides in avoiding overlap between an absorption spectrum of the hole transporting material and a light emission spectrum of the electron transporting material. In this case, it is preferred not only that the spectrums do not overlap each other, but also that the positional relationship between the spectrums be such that the absorption spectrum of the hole transporting material is on the shorter-wavelength side of the light emission spectrum of the electron transporting material.
[0032] As a means for achieving the object of the present invention, it is important to adopt a device arrangement enabling the dopant capable of triplet light emission to easily trap the carriers in improving the light emission efficiency of the above-described triplet light emitting device of the present invention.
[0033] Accordingly, the present invention is characterized in that both the highest occupied molecular orbit level and the lowest unoccupied molecular orbit level of the light emitting material capable of emitting light from a triplet excited state are in the energy gap between the highest occupied molecular orbit level and the lowest unoccupied molecular orbit level of the electron transporting material.
[0034] As still another means for achieving the object of the present invention, the light emitting device is characterized in that the value of ionization potential of the hole transporting material is equal to or larger than the value of ionization potential of the light emitting material capable of emitting light from a triplet excited state.
[0035] Further, as another means for achieving the object of the present invention, the light emitting device is characterized in that the absolute value of a value indicating the lowest unoccupied molecular orbit level of the hole transporting material is smaller by 0.2 eV or more than the absolute value of a value indicating the lowest unoccupied molecular orbit level of the electron transporting material.
[0036] It is more preferable to use a device arrangement corresponding to a combination of these means, i.e., an arrangement in which the value of ionization potential of the hole transporting material is equal to or larger than the value of ionization potential of the light emitting material capable of emitting light from a triplet excited state, and the absolute value of a value indicating the lowest unoccupied molecular orbit level of the hole transporting material is smaller by 0.2 eV or more than the absolute value of a value indicating the lowest unoccupied molecular orbit level of the electron transporting material.
[0037] In view of the above description, the present invention is characterized in that used as the preferred hole transporting material is one selected from the group consisting of 4,4′,4″-tris(N-carbazole)triphenylamine, 4,4′-bis[N,N-bis(3-methylphenyl)-amino]-diphenylmethane, 1,3,5-tris[N,N-bis(2-methylphenyl)-amino]-benzene, 1,3,5-tris[N,N-bis(3-methylphenyl)-amino]-benzene; and 1,3,5-tris[N,N-bis(4-methylphenyl)-amino]-benzene.
[0038] Further, the present invention is characterized in that used as the electron transporting material is one selected from the group consisting of 2,2′,2″-(1,3,5-benzenetriyl)tris-[1-phenyl-1H-benzoimidazole], lithiumtetra(2-(2-hydroxyphenyl)benzooxazolatoboron, bis(2-(2-hydroxyphenyl)benzooxazolato)(triphenylsilanolato)aluminum, bis(2-(2-hydroxyphenyl)benzothiazolato)(triphenylsilanolato)aluminum, 2-(2-hydroxyphenyl)benzooxazolatolithium, (2-(2-hydroxyphenyl)benzooxazolato)-diphenylboron, tris(8-quinolinolato)-aluminum, bis(2-methyl-8-quinolinolato)(triphenylsilanolato)aluminum, bis(2-methyl-8-quinolinolato)(4-phenylphenolato)aluminum, lithiumtetra(2-methyl-8-hydroxy-quiriolinato)boron, (2-methyl-8-quinolinolato)-diphenylboron, and bis(2-methyl-8-quinolinolato)aluminiumhydroxide.
[0039] Further, in the device of the present invention, it is effective to use the hole transporting material and the electron transporting material in combination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] In the accompanying drawings:
[0041] FIG. 1 is a diagram showing the device structure of a two-layer triplet light emitting device in accordance with the present invention;
[0042] FIG. 2 is a diagram showing HOMO and LUMO energy levels;
[0043] FIG. 3 is an energy gap diagram of the device;
[0044] FIGS. 4A and 4B are diagrams showing the positional relationship between the light emission spectrum of a host material and the absorption spectrum of a hole transporting material;
[0045] FIGS. 5A to 5D are graphs showing an initial characteristic and a light emission spectrum in Embodiment 1;
[0046] FIGS. 6A to 6D are graphs showing an initial characteristic and a light emission spectrum in Embodiment 2;
[0047] FIGS. 7A to 7D are graphs showing an initial characteristic and a light emission spectrum in Embodiment 3;
[0048] FIGS. 8A to 8D are graphs showing an initial characteristic and a light emission spectrum in Embodiment 4;
[0049] FIGS. 9A to 9D are graphs showing an initial characteristic and a light emission spectrum in Comparative Example 1;
[0050] FIGS. 10A to 10D are graphs showing an initial characteristic and a light emission spectrum in Comparative Example 2;
[0051] FIGS. 11A to 11D are graphs showing an initial characteristic and a light emission spectrum in Comparative Example 3; and
[0052] FIG. 12 is a diagram showing the device structure of a conventional triplet light emitting device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] An embodiment mode of the present invention will be described in detail. An organic light emitting device may have at least one of an anode and a cathode made transparent to enable emitted light to be output. However, the embodiment mode of the present invention will be described with respect to a device structure in which a transparent anode is formed on a substrate and light is output through the anode. In actuality, the present invention can also be applied to a structure in which a cathode is formed on a substrate and light is output through the cathode, a structure in which light is output from the side opposite from a substrate, and a structure in which light is output through opposed electrodes.
[0054] As described above, the present invention is characterized in that use of a hole blocking layer in a triplet light emitting device is avoided ( FIG. 1 ). However, the present invention is different from a method of fabricating a device designed only by removing the hole blocking layer from the conventional device structure ( FIG. 12 ).
[0055] The conventional triplet light emitting device and the two-layer device of the present invention have different recombination regions. In the conventional triplet light emitting device, a hole blocking layer is used and the carrier recombination region corresponds to the interface between the light emitting layer and the hole blocking layer. In contrast, in the device structure proposed in the present invention, the carrier recombination region corresponds to the interface between the hole transporting layer and the electron transporting material provided as a host material.
[0056] Therefore it is important to consider a light emission mechanism in triplet light emitting devices. In general, two kinds of light emission mechanisms are conceivable as light emission mechanisms in devices using a guest-host light emitting layer using a dopant (guest).
[0057] The first light emission mechanism is emission from the dopant caused by transfer of energy from the host. In this case, both the carriers are injected into the host to form excited molecules of the host. The energy of the excited molecules is transferred to the dopant. The dopant is excited by the energy and emits light when deactivated. In triplet light emitting devices, the dopant is a material for emitting phosphorescence via a triplet excited molecule state, and light is therefore emitted by phosphorescence.
[0058] In the light emission mechanism based on transfer of energy, the magnitude of overlap of the light emission spectrum of the host material and the absorption spectrum of the dopant material is important. The positional relationship between the highest occupied molecular orbit (HOMO) and the lowest unoccupied molecular orbit (LUMO) in the host material and the dopant material is not important.
[0059] In this specification, the value of ionization potential measured by photoelectron spectrometry in atmospheric air is used as the value of the HOMO. The absorption ends of the absorption spectrum define the energy difference between the HOMO and the LUMO (hereinafter referred to as “energy gap value”). Therefore the value obtained by subtracting the energy gap value estimated from the absorption ends of the absorption spectrum from the value of ionization potential measured by photoelectron spectrometry is used as the value of the LUMO. In actuality, these values (HOMO (ionization potential), LUMO (energy gap value)) are negative since they are measured with reference to the vacuum level. However, they are shown as absolute values throughout the specification. Conceptual views of the HOMO, the LUMO, and the energy gap values are as shown in FIG. 2 .
[0060] If both the energy levels of the HOMO and LUMO of the dopant material are placed in the energy gap between the HOMO and LUMO in the host material, a direct-recombination light emission mechanism, i.e., direction recombination of the carriers on the dopant when the carriers are trapped on the dopant, occurs as well as the above-described light emission mechanism based on transfer of energy from the host to the dopant. This is the second light emission mechanism.
[0061] However, in a case where the dopant material and the host material are in such an energy level relationship, it is ordinarily difficult to separately determine the contribution of each light emission mechanism to emission of light since transfer of energy is allowed according to the conditions, and there is a possibility of both the light emission mechanisms contributing to light emission.
[0062] A case where a triplet light emitting device is emitting light by the energy transfer mechanism (first light emission mechanism) will be discussed. In the conventional device structure, since the carrier recombination region is the interface between the light emitting layer and the hole blocking layer, there is a possibility of transfer of energy to the hole blocking material as well as transfer of energy from the host material to the dopant material. However, since the absorption spectrum of the hole blocking material is on an extremely short wavelength side, there is, therefore, no overlap between the absorption spectrum of the hole blocking layer and the light emission spectrum of the host material reported with respect to the conventional triplet light emitting devices, and there is no possibility of transfer of energy between the host material and the hole blocking material. That is, the conventional triplet light emitting devices have such device structure that transfer of energy from the host material to the hole blocking material does not occur.
[0063] In contrast, in the device structure in accordance with the present invention, the carrier recombination region is the interface between the hole transporting layer containing a hole transporting material and the electron transporting and light emitting layer containing a host material. In the device of the present invention, therefore, there is a possibility of transfer of energy from the host material to the hole transporting material. If energy transfer from the host material to the hole transfer material occurs, efficient emission of light cannot be achieved.
[0064] The relationship between the magnitudes of the energy gap value of the host material and the energy gap value of the hole transporting material can be referred to as a rough guide with respect to energy transfer. If the energy gap value of the host material is smaller than the energy gap value of the hole transporting material, it is difficult to excite the hole transporting material by transfer of energy from the host material. For this reason, it is preferred that the hole transporting material have an energy gap value larger than that of the host material in order to avoid transfer of energy from the host material to the hole transporting material.
[0065] FIG. 3 is a relating energy diagram. The materials may be selected so that the energy gap value A of the hole transporting material is larger than the energy gap value B of the host material, as shown in FIG. 3 .
[0066] A method of selecting, as a condition for prevention of energy transfer between the host and hole transporting materials, a combination of materials such that there is no overlap between the light emission spectrum of the host material and the absorption spectrum of the hole transporting material may be used. When this method is used, it is preferred that the absorption spectrum of the hole transporting material is placed on the shorter-wavelength side of the light emission spectrum of the electron transporting material.
[0067] FIGS. 4A and 4B illustrate this condition. The positional relationship between the spectrums in a case where transfer of energy occurs between the host material and the hole transporting material is indicated in FIG. 4A , and the positional relationship between the spectrums in a case where transfer of energy does not occur between the host material and the hole transporting material is indicated in FIG. 4B . According to the present invention, the positional relationship of FIG. 4B is preferred.
[0068] It is important to consider a condition other than those described above if a host material is selected such that both the energy levels of the HOMO and LUMO of the dopant material are placed in the energy gap between the HOMO and LUMO of the host material, because in such a case the direct-recombination light emission mechanism (second light emission condition) is taken into consideration.
[0069] In such a case, it is suitable to set the value of the ionization potential indicating the HOMO of the hole transporting material to a larger value in order to facilitate injection of the hole carrier from the hole transporting material to the dopant material. That is, a combination of materials is selected such that the ionization potential of the hole transporting material is higher than that of the dopant material. If the ionization potential of the hole transporting material is excessively high, the facility with which holes are injected from the anode into the hole transporting material is reduced. In such a case, a hole injection layer may be provided between the anode and the hole transporting layer to facilitate injection.
[0070] It is thought that the dopant traps the electron carrier through the electron-transporting host. In a case where electrons not trapped by the dopant reach the interface on the hole transporting layer by moving through the electron transporting layer, the electrons reaching the interface enter the hole transporting layer if the difference between the LUMO level of the hole transporting material and the LUMO level of the host material is small. In such a case, electrons are not confined in the electron transporting layer and efficient recombination cannot be achieved. To avoid such a situation, it is desirable to set the difference between the LUMO levels of the hole transporting material and the electron transporting material which is a host material to a value large enough to block electrons. Preferably, this difference is 0.2 eV or greater.
[0071] More concrete examples of a method of fabricating the triplet light emitting device of the prevent invention and materials used in the device will next be described.
[0072] A device fabrication method of the present invention shown in FIG. 2 is performed as described below. First, a hole transporting material is deposited on a substrate with an anode (ITO). Next, an electron transporting material (host material) and a triplet light emitting material (dopant) are codeposited. Finally, a cathode is formed by deposition. The dopant concentration at the time of codeposition of the host material and the dopant material is adjusted to about 8 wt %. Finally, sealing is performed to complete the organic light emitting device.
[0073] Materials which can be suitably used as a hole injection material, a hole transporting material, an electron transporting material (host material), and a triplet light emitting material (dopant material) in the device of the present invention are shown below. However, materials usable in the device of the present invention are not limited to those shown below.
[0074] As the effective hole injecting material among organic compounds, there is a porphyrin-based compound, phthalocyanine (hereinafter referred to as “H 2 Pc”), copper phthalocyanine (hereinafter referred to as “CuPc”), or the like. In addition, a material which has a smaller ionization potential than the hole transporting material to be used and a hole transporting function can also be used as the hole injecting material. There is also used a material obtained by chemically doping a conductive polymer compound, for example, polyaniline or polyethylene dioxythiophene (hereinafter referred to as “PEDOT”) doped with sodium polystyrene sulfonate (hereinafter referred to as “PSS”). Alternatively, a polymer compound as an insulator is effective in flattening the anode, so that polyimide (hereinafter referred to as “PI”) is widely used. Furthermore, there is also used such an inorganic compound as a metal thin film of gold, platinum, or the like or a microthin film of aluminum oxide (hereinafter referred to as “alumina”).
[0075] As the effective hole transporting material, there is a material having an energy gap value larger than that of the electron transporting material to be used as the host material. Also, it is preferable that the material has a larger ionization potential than the light emitting material or the absolute value of LUMO thereof is smaller than that of the electron transporting material by 0.2 eV or more.
[0076] Examples of the hole transporting material having a large energy gap value which is preferable for the device of the present invention include: 4,4′,4″-tris(N-carbazole)triphenylamine (hereinafter referred to as “TCIA”) represented by the following structural formula 1; 1,3,5-tris[N,N-bis(2-methylphenyl)-amino]-benzene (hereinafter referred to as “o-MTDAB”) represented by the following structural formula 2; 1,3,5-tris[N,N-bis(3-methylphenyl)-amino]-benzene (hereinafter referred to as “m-MTDAB”) represented by the following structural formula 3; 1,3,5-tris[N,N-bis(4-methylphenyl)-amino]-benzene (hereinafter referred to as “p-MTDAB”) represented by the following structural formula 4; and 4,4′-bis[N,N-bis(3-methylphenyl)-amino]-diphenylmethane (hereinafter referred to as “BPPM”) represented by the following structural formula 5.
[0000]
[0077] On the other hand, 4,4′-bis[N-(3-methylphenyl)-N-phenyl-amino]-biphenyl (hereinafter referred to as “TPD”) which is an aromatic amine-based compound and used most widely and α-NPD as its derivative have smaller energy gap values than the compounds represented by the structural formulae 1 to 5, and are therefore difficult to use for the device of the present invention. Table 1 shows the energy gap values (actually measured values) of the compounds represented by the structural formulae 1 to 5, A-NPD, and TPD.
[0000]
TABLE 1
Material
Energy gap [eV]
TCTA
3.3
o-MTDAB
3.6
m-MTDAB
3.5
p-MTDAB
3.6
BPPM
3.6
TPD
3.1
α-NPD
3.1
[0078] A stable material is preferred as an electron transporting material used as a host. For example, a selection may be made from a number of metal complexes of high stability. Materials used as a host material must have an energy gap value larger than that of the triplet light emitting material, which is a dopant. Different host materials are selected according to the light emitting materials used. Examples of electron transporting materials usable as a host are shown below.
[0079] According to the present invention, as an example of a material that can be used as the host material with respect to a blue light emitting material, there is a material in which light emission spectrum can be seen at an extremely short wavelength as of ultraviolet region, for example, 2,2′,2″-(1,3,5-benzenetrile)tris-[α-phenyl-1H-benzimidazole] (hereinafter referred to as “TPBI”) represented by the following structural formula 6.
[0000]
[0080] According to the present invention, examples of the host material with respect to the green light emitting material include: lithiumtetra(2-(2-hydroxyphenyl)benzooxazolatoboron (hereinafter referred to as “LiB(PBO) 4 ”) represented by the following structural formula 7; bis(2-(2-hydroxyphenyl)benzooxazolato)(triphenylsilanolato)aluminum (hereinafter referred to as “SAlo”) represented by the following structural formula 8; bis(2-(2-hydroxyphenyl)benzothiazolato)(triphenylsilanolato)aluminum (hereinafter referred to as “SAlt”) represented by the following structural formula 9; 2-(2-hydroxyphenyl)benzooxazolatolithium (hereinafter referred to as “Li(PBO)”) represented by the following structural formula 10; and (2-(2-hydroxyphenyl)benzooxazolato)-diphenylboron (hereinafter referred to as “B(PBO)Ph 2 ”) represented by the following structural formula 11. In addition to these, it is possible to use as the host material the material that can emit blue light.
[0000]
[0081] According to the present invention, examples of the host material with respect to the red light emitting material include: Alq represented by the following structural formula 12; bis(2-methyl-8-quinolinolato)(triphenylsilanolato)aluminum (hereinafter referred to as “SAlq”) represented by the following structural formula 13; bis(2-methyl-8-quinolinolato)(4-phenylphenolato)aluminum (hereinafter referred to as “BAlq”) represented by the following structural formula 14; lithiumtetra(2-methyl-8-hydroxy-quinolinato)boron (hereinafter referred to as “LiB(mq) 4 ”) represented by the following structural formula 15; (2-methyl-8-quinolinolato)-diphenylboron (hereinafter referred to as “BmqPh”) represented by the following structural formula 16; and bis(2-methyl-8-quinolinolato)aluminiumhydroxide (hereinafter referred to as “Almq 2 (OH)”) represented by the following structural formula 17. In addition to these, it is possible to use as the host material the material that can emit blue light or the material that can emit green light.
[0000]
[0082] Note that the energy gap values (actually measured values) in accordance with some of the host materials described above are shown in Table 2.
[0000]
TABLE 2
Material
Energy gap [eV]
TPBI
3.5
LiB(PBO) 4
3.1
SAlo
3.2
SAlt
3.0
Alq
2.7
SAlq
3.0
LiB(mq) 4
3.0
[0083] Examples of the triplet light emitting material as a dopant mostly include complexes having a central metal of iridium or platinum. However, any material may be adopted as long as it emits phosphorescence at a room-temperature. As such a material, for example, there are PtOEP, Ir(ppy) 3 , bis(2-phenylpyridinato-N,C 2′ )acetylacetonatoiridium (hereinafter referred to as “acacIr(ppy) 2 ”), bis(2-(4′-trile)-pyridinato-N,C 2′ )acetylacetonatoiridium (hereinafter referred to as “acacIr(tpy) 2 ”), and bis(2-(2′-benzothienyl)pyridinato-N,C 3′ )acetylacetonatoiridium (hereinafter referred to as “acacIr(btp) 2 ”).
[0084] Note that the energy gap values (actually measured values) in accordance with the dopant materials described above are shown in Table 3.
[0000]
TABLE 3
Material
Energy gap [eV]
Ir(ppy) 3
2.4
acacIr(ppy) 2
2.4
acacIr(tpy) 2
2.4
acacIr(btp) 2
2.3
[0085] As the electron injecting material, the electron transporting material described above can be used. However, such an electron transporting material (BCP, OXD7, or the like) that is used as the hole blocking material is low in stability, and thus it is inappropriate as the electron injecting material. In addition, there is often used a microthin film made of an insulator, for example, alkali metal halide such as lithium fluoride or alkali metal oxide such as lithium oxide. Also, an alkali metal complex such as lithium acetylacetonate (hereinafter referred to as “Li(acac)”) or 8-quinolinolato-lithium (hereinafter referred to as “Liq”) is effective.
[0086] A combination of materials is selected from the above-described materials having the desired functions to be used in the organic light emitting device of the present invention. Thus, a high-efficiency organic light emitting device which can be fabricated by a simpler process in comparison with the conventional triplet light emitting devices, which has improved stability, and which has a light emission efficiency substantially equal to that of the conventional triplet light emitting devices can be provided.
[0087] Embodiments of the organic light emitting device of the present invention shown in FIG. 2 will be described below.
Embodiment 1
[0088] First, a 40 nm-thick layer of BPPM, which is a hole transporting material, is deposited on glass substrate 101 with ITO film formed as anode 102 and having a thickness of about 100 nm. Hole transporting layer 103 is thereby formed.
[0089] After fabrication of the hole transporting layer, acacIr(tpy) 2 , which is a triplet light emitting material, and TPBI, which is an electron transporting material (host material), are codeposited in proportions of about 2:23 (weight ratio). That is, acacIr(tpy) 2 is dispersed at a concentration of about 8 wt % in TPBI. A 50 nm-thick codeposited film is thereby formed. This film is electron transporting and light emitting layer 104 .
[0090] Finally, Mg and Ag are codeposited at an atomic ratio of 10:1 to form cathode 105 . A 150 nm-thick film for cathode 205 is thereby formed. A triplet light emitting device which emits green light derived from acacIr(tpy) 2 is thus obtained.
[0091] FIGS. 5A to 5D are graphs showing an initial characteristic and a light emission spectrum in this device. Even though the simple two-layer structure was formed, a device characteristic of high efficiency, i.e., a maximum external quantum efficiency of about 10%, was exhibited.
Embodiment 2
[0092] A device in accordance with the present invention was fabricated by using a hole transporting material (satisfying the condition in accordance with the present invention) different from that in Embodiment 1.
[0093] First, a 40 nm-thick layer of o-MTDAB, which is a hole transporting material, is deposited on glass substrate 101 with ITO film formed as anode 102 and having a thickness of about 100 nm. Hole transporting layer 103 is thereby formed.
[0094] After fabrication of the hole transporting layer, acacIr(tpy) 2 , which is a triplet light emitting material, and TPBI, which is an electron transporting material (host material), are codeposited in proportions of about 2:23 (weight ratio). That is, acacIr(tpy) 2 is dispersed at a concentration of about 8 wt % in TPBI. A 50 nm-thick codeposited film is thereby formed. This film is electron transporting and light emitting layer 104 .
[0095] Finally, Mg and Ag are codeposited at an atomic ratio of 10:1 to form cathode 205 . A 150 nm-thick film for cathode 205 is thereby formed. A triplet light emitting device which emits green light derived from acacIr(tpy) 2 is thus obtained.
[0096] FIGS. 6A to 6D are graphs showing an initial characteristic and a light emission spectrum of this device. A high-efficiency device can be fabricated as in Embodiment 1.
Embodiment 3
[0097] An organic light emitting device in accordance with the present invention was fabricated by using as a host material a hole transporting material (satisfying the condition in accordance with the present invention) different from that in Embodiment 1. The fabrication method is the same as that in Embodiments 1 and 2. BPPM is used as a hole transporting material, SAlt is used as a host, i.e., the electron transporting material, and acacIr(tpy) 2 is used as a dopant. A triplet light emitting device which emits green light derived from acacIr(tpy) 2 can be obtained.
[0098] FIGS. 7A to 7D show an initial characteristic and a light emission spectrum of this device. A high-efficiency device having a light emission efficiency substantially equal to that in the conventional triplet light emitting devices can be fabricated as in Embodiment 1 or 2.
Embodiment 4
[0099] By using a triplet light emitting material different from Embodiment 1, 2, or 3 as a dopant, an organic light emitting device having a light emission color different from that of Embodiment 1, 2, or 3 is prepared. The method for preparation is the same as that of Embodiments 1, 2, and 3. BPPM is used as the hole transporting material, TPBI is used as the electron transporting material, and bis(2-(2′,4′-difluorophenyl)pyridinato-N,C2′)picolatoiridium is used as the dopant. It is possible to obtain the triplet light emitting device which emits blue light derived from the dopant material.
[0100] FIGS. 8A to 8D show an initial characteristic and a light emission spectrum of this device. A high-efficiency device having a light emission efficiency substantially equal to, that in the conventional triplet light emitting devices can be fabricated as in Embodiment 1, 2, or 3.
Comparative Example 1
[0101] A device of a structure similar to that of the conventional triplet light emitting device shown in FIG. 12 was manufactured and its characteristics were compared with those of the devices of the present invention.
[0102] First, a 40 nm-thick layer of α-NPD, which is a hole transporting material, is deposited on glass substrate 1101 with ITO film formed as anode 1102 and having a thickness of about 100 nm. Hole transporting layer 1103 is thereby formed.
[0103] After fabrication of the hole transporting layer, acacIr(tpy) 2 , which is a triplet light emitting material, and CBP, which is a host material, are codeposited in proportions of about 2:23 (weight ratio). That is, acacIr(tpy) 2 is dispersed at a concentration of about 8 wt % in CBP. A 50 nm-thick codeposited film is thereby formed. This film is light emitting layer 1104 .
[0104] After the formation of the light emitting layer, a 20 nm-thick film of BCP, which is a hole blocking material, is deposited to form hole blocking layer 1105 . A 0.30 nm-thick film of Alq, which is an electron transporting material is deposited to form electron transporting layer 1106 .
[0105] Finally, Mg and Ag are codeposited at an atomic ratio of 10:1 to form cathode 1107 . A 150 nm-thick film for cathode 1107 is thereby formed. A triplet light emitting device which emits green light derived from acacIr(tpy) 2 is thus obtained.
[0106] FIGS. 9A to 9D show an initial characteristic and a light emission spectrum of this device. From comparison between this comparative example and each of Embodiments 1, 2, and 3, it can be understood that the device of the present invention in each Embodiment has the same high efficiency as the conventional device. It was confirmed that sufficiently high device characteristics were exhibited even though no hole blocking layer was used.
Comparative Example 2
[0107] In this comparative example, characteristics of a triplet light emitting device of a two-layer structure in which a hole transporting material not satisfying the device conditions in accordance with the present invention is used are examined.
[0108] The same fabrication method as that in the Embodiments of the present invention is used. However, a combination of a hole transporting material and a host material is used such that the energy gap value of the hole transporting material used is smaller than that of the host material. TPD is used as the hole transporting material, TPBI is used as the host material, which is an electron transporting material, and acacIr(tpy) 2 is used as a dopant.
[0109] FIGS. 10A to 10D show an initial characteristic and a light emission spectrum of this device. The device using TPD as a hole transporting material has a considerably low light emission efficiency for a triplet light emitting device. A spectral component (about 400 nm) corresponding to emission from TPD other than emission from acacIr(tpy) 2 is observed, as seen in the light emission spectrum. A reduction in efficiency results from this. Thus, the initial characteristic of the device is inferior if a material not satisfying the condition is used.
Comparative Example 3
[0110] In this comparative example, characteristics of a triplet light emitting device of a two-layer structure in which a hole transporting material not satisfying the device conditions in accordance with the present invention is used as in Comparative Example 2 are examined.
[0111] The same fabrication method as that in the Embodiments of the present invention is used. However, a combination of a hole transporting material and a host material is used such that the energy gap value of the hole transporting material used is smaller than that of the host material. In this example, α-NPD is used as the hole transporting material, TPBI is used as the host material, which is an electron transporting material, and acacIr(tpy) 2 is used as a dopant.
[0112] FIGS. 11A to 11D show an initial characteristic and a light emission spectrum of this device. The device using α-NPD as a hole transporting material has a considerably low light emission efficiency for a triplet light emitting device, as in Comparative Example 2. A spectral component, (about 440 nm) corresponding to emission from α-NPD which is a hole transporting material is observed, as in Comparative Example 2. A reduction in efficiency results from this. Thus, the initial characteristic of the device is inferior if a material not satisfying the condition is used.
[0113] If the present invention is carried out, a triplet light emitting device having a light emission efficiency substantially equal to that of the conventional triplet light emitting devices can be obtained in a simple device structure. Also, the layer in which an unstable material is used is removed to enable a stable organic light emitting device to be provided.
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A triplet light emitting device which has high efficiency and improved stability and which can be fabricated by a simpler process is provided by simplifying the device structure and avoiding use of an unstable material. In a multilayer device structure using no hole blocking layer conventionally used in a triplet light emitting device, that is, a device structure in which on a substrate, there are formed an anode, a hole transporting layer constituted by a hole transporting material, an electron transporting and light emitting layer constituted by an electron transporting material and a dopant capable of triplet light emission, and a cathode, which are laminated in the stated order, the combination of the hole transporting material and the electron transporting material and the combination of the electron transporting material and the dopant material are optimized.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of optical radiometry. Optical radiometry is the science of measuring the surface temperatures of bodies by means of the optical radiation which they emit. The word "optical" refers to electromagnetic radiation covering the spectrum from gamma rays and X-rays through the ultraviolet, visible and infrared regions, ending at a wavelength of about 1 mm where radio wavelengths begin.
In connection with temperature measurements, the word "pyrometry" is often applied to that branch of radiometry which deals with hot or incandescent surfaces. "Optical pyrometry" (or "brightness pyrometry") makes use of visible light to measure incandescent body temperatures, while "radiation pyrometry" describes the same process but using infrared radiation. The term "radiometry" is broader than these, for it includes measurements of cold bodies.
Many optical pyrometers have been devised which measure visible light simultaneously in two wavelength regions. Use is made of the ratio of light intensities in order to overcome certain problems in the use of a single wavelength region. Such devices are called "two-color pyrometers" or "ratio pyrometers."
The ratio method may equally well be used with cooler objects, making use of two wavelength bands in the infrared region. In this case, the method is referred to as "two-wavelength radiometry" although the term "two-color radiometry" is often used. Other terms are also encountered which describe the above methods. Examples of these are "dual-wavelength," "two-band," "multi-spectral," "dichromatic" and "spectral radiance ratio" which are used with either "radiometry" or "pyrometry."
Ratio-radiometry has been in use for many decades as an extension of the basic radiometric method of temperature measurement. Its purpose is primarily to eliminate the effects of target surface emissivity by assuming that it is the same in both wavelength regions which are being sampled. Also, the method is able to compensate for any difference in emissivities, provided that the ratio of these is known and remains constant during the measurement.
The subjects of optical and two-wavelength radiometry have been described very fully in the prior literature, examples being the technical papers by Hornbeck, "Optical Methods of Temperature Measurement," Applied Optics, Volume 5, No. 2, February 1966, pages 179-186, and also by Horman, "Temperature Analysis from Multispectral Infrared Data," Applied Optics, Volume 15, No. 9, September 1976, pages 2099-2104. Therefore, these subjects are only briefly discussed herein.
The process of radiant emission from a theoretically perfect emitting surface (a blackbody) is described by Planck's Radiation Law,
J.sub.λ =c.sub.1 λ.sup.-5 (e.sup.c.sbsp.2.sup./λT -1).sup.-1 ( 1)
where
J.sub.λ =radiant intensity at wavelength λ (watts/cm 3 )
c 1 =3.7×10 -12 (watts×cm 2 )
c 2 =1.43 (cm×deg)
λ=wavelength (cm)
e=2.718 (dimensionless)
T=absolute temperature (deg. K).
For the temperature and wavelength ranges in which we will be interested, the exponential term in parentheses is sufficiently greater than unity that Equation (1) may be written:
J.sub.λ =c.sub.1 λ.sup.-5 /e.sup.c.sbsp.2.sup./λT ( 2)
For a non-blackbody surface, we introduce an emissivity value, E.sub.λ, which reduces the emission by a given amount at each wavelength:
J.sub.λ =E.sub.λ c.sub.1 λ.sup.-5 /e.sup.c.sbsp.2.sup./λT ( 3)
Most often, the emissivity will vary with wavelength throughout the spectral region of interest. If it is relatively constant over some region, the surface is referred to as a greybody over that region. The emissivity of a surface may also vary with surface texture and with viewing angle, and frequently (as with metals) it will change as the surface temperature changes.
Assuming, however, that an emissivity E 1 characterizes a surface over some wavelength band centered on wavelength λ 1 and that E 2 is the corresponding value at λ 2 , we may write for the radiant intensities in the respective bands:
J.sub.1 =E.sub.1 c.sub.1 λ.sub.1.sup.-5 /e.sup.c.sbsp.2.sup./λ.sbsp.1.sup.T
and
J.sub.2 =E.sub.2 c.sub.1 λ.sub.2.sup.-5 /e.sup.c.sbsp.2.sup./λ.sbsp.2.sup.T
of which the ratio can be reduced to:
J.sub.1 /J.sub.2 =(E.sub.1 E.sub.2)(λ.sub.2 /λ.sub.1).sup.5 e.sup.(c.sbsp.2.sup./T)(1/λ.sbsp.2.sup.-1/λ.sbsp.1.sup.)
The quantities λ 1 and λ 2 are known and are constant as is c 2 . We make the same assumption for E 1 and E 2 and can hence replace them by new constants for brevity:
J.sub.1 /J.sub.2 =Ae.sup.B/T
Taking logarithms of both sides, we have:
log.sub.e (J.sub.1 /J.sub.2)=(log A)+B/T
or
T=B/log.sub.e (J.sub.1 /AJ.sub.2) (4)
where
A=(E.sub.1 /E.sub.2)(λ.sub.2 /λ.sub.1).sup.5
and
B=c.sub.2 (1/λ.sub.2 -1/λ.sub.1)
Equation (4) is the "working equation" of ratio pyrometry, just as Equation (3) is for "monochromatic" pyrometry, the difference being that the latter contains E explicitly. However, the user should be aware that in the former case, although E 1 and E 2 are allowed to vary throughout the course of the measurements, their ratio must remain constant.
In principle, one has only to measure the respective radiant intensities in the two wavelength bands, over some defined part of the target surface, in order to be able to deduce the temperature at this region. If the wavelength bands are not widely separated in the spectrum, one can safely assume that E 1 /E 2 =1, unless one has prior knowledge to the contrary.
In practice, there are two basic ways of implementing the measurement, each with its advantages and disadvantages. Either a simultaneous measurement may be made by two detector/filter combinations, or a single detector may be used to view the surface sequentially through alternating filters.
In the simultaneous method, care must be taken to ensure that the detector responses are similar or that any differences are calibrated out. The method offers the advantages that there are no moving mechanical parts and that the response time of the system is limited by that of the basic detection system rather than by "chopping frequency" considerations in connection with the motions of the filters. Although individual detectors are frequently chopped in order to eliminate thermal drift problems, this can be done at higher frequencies than one can use in filter alternation.
The sequential method eliminates any uncertainties due to possible detector drift but may introduce questions of reliability if the rotating or oscillating filter system is not carefully designed and tested.
The second method is often used in mass-produced two-color pyrometers for use by semi-skilled personnel, where the design cost is easily amortized and where periodic calibration is not feasible.
For laboratory uses of band-ratio radiometry, the method is best implemented by use of a two-detector system, along with appropriate calibration procedures, and this is the approach taken in the present invention.
SUMMARY OF THE INVENTION
The present invention differs from previous ratio-radiometers in that it uses two different materials, having different spectral transmittance properties, in a bifurcated or trifurcated fiber optical radiation guide to achieve the same effect as conventional optical filters. This is a considerable advantage because it is not always convenient or economical to provide the desired optical filters, particularly in the near-infrared region from about 1-3 micrometers. Moreover, the use of the fibers to perform the filtering function permits a closer placement of the fiber bundle end faces to their respective detectors. This would not be the case if filters were interposed between the end faces and the detectors. The close placement avoids the spreading loss of radiation which would occur in the intervening space if filters were used. Such losses ordinarily occur because the radiation emerging from most optical fibers is spread into rather large angles (typically, 50 or 60 degrees) compared with other optical elements, such as lenses.
Another feature of the invention is the use of two identical detectors in the separate branches of the optical fiber bundle. The use of identical detectors is desirable on the basis that their physical and electrical properties can be matched. Problems are thereby avoided concerning unequal detector sizes, sensitivities, response times, temperature characteristics, aging properties and so forth.
The use of the trifurcated fiber optical guide provides a third optical branch which is used to convey an image of a luminous aperture to the target surface, in coincidence with the detector images, to be used for aiming or positioning purposes. A lens or other focusing system may be provided to allow the formation of an image of the remote or common end of optical fiber bundle onto a defined area of a target whose temperature is to be measured.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention will be had from the following detailed description with reference to the accompanying drawings, in which:
FIG. 1 is a block and schematic diagram of a preferred form of the band-ratio radiometer according to the invention;
FIG. 2 is a graph showing the spectral response of lead sulfide detectors at room temperature;
FIG. 3 is a graph showing the ideal spectral transmittance curves of two types of glass which may be used in making the bifurcated or trifurcated optical fiber bundle used in the invention; and
FIG. 4 is a graph showing the effective spectral sensitivities of lead sulfide when used with the glasses represented by the curves in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and, more particularly, to FIG. 1, there is shown a trifurcated optical fiber bundle 10 having a common end 11 and three branched ends 12, 13 and 14. The ends of the optical fibers of each branch are interspersed in the common end 11. A focusing system 15 comprising an objective lens 16 forms an image of the common end of the bundle onto a defined area of a target 17 whose temperature is to be measured. The branched ends 12 and 13 are immediately proximate respective detectors 18 and 19, while the branched end 14 is adjacent a light source 20. Detectors 18 and 19 are connected to the inputs of conventional divider and linearizing amplifier circuitry 21, the output of which may be displayed by a meter 22.
Each fiber optical bundle forming a branch of the trifurcated bundle is composed of a group of continuous, hair-like strands of clear optical material, such as one of the many forms of glass. Each fiber has the ability to transmit optical radiation from one end to the other, even though the fiber is bent. The properties of such fibers are well known in the art and have been widely documented. An example is the technical paper by Kapany, entitled "Fiber Optics," Scientific American, Volume 203, No. 5, November 1960, pages 72-81.
The purpose of interspersing the fibers at the remote or common end is to achieve spatial coincidence of the images of the two detectors 18 and 19 and the light source 20 at this end. Each "image" in this case is composed of the scrambled pictorial elements of whatever object the other ends of the fibers are aimed at. The remote end of the bundle, therefore, carries scrambled image elements from both detectors and from the light source. When this end is in turn re-imaged onto a defined portion of a target surface by the lens 16, for example, the detectors and light source are all ensured of being imaged onto that same portion.
In this way, we avoid the problem of parallax error which arises when two detectors (and possibly an aiming device) are separately directed toward and focused upon a specific target area. In such a case, if a new target distance is to be used, all three devices must be re-directed as well as re-focused. In the present invention, only one lens need be re-focused for a new target distance.
Those who are familiar with fiber optics will recognize that it is not possible to achieve perfect scrambling of the separate images at the remote end of the bundle. Part of the reason is that the mixing of the fiber ends is done manually during manufacture and it is difficult to avoid random local clusters of fibers from the same branch. Besides this, even if the mixing were uniform, the individual fiber ends are finite in size and, therefore, the image as projected onto the target possesses a "microstructure" or graininess.
For situations where this may be a problem, the solution is offered by the use of an "optical mixer" or "homogenizer" in the form of a short length of transparent rod whose walls and ends are optically polished. Its diameter is approximately that of the fiber bundle end face and its length may be equal to several times its diameter. For use with infrared-transmitting fibers, such a rod may be made of sapphire, quartz, ruby or other infrared-transmitting materials which are known in the art.
Such a rod thus serves as a large diameter single fiber. Radiation is transmitted from end to end largely by internal reflection from the side walls, the more so if the rod is longer. By this means, better mixing of the ray paths from the individual fibers is ensured. In use, the rod is placed in contact with, or in proximity to, the remote end face of the fiber bundle. Its other end is then to be focused onto the defined target area.
Turning now to the subject of the radiation detectors themselves, a variety of such detectors is known to practitioners of the optical detection art, with various physical properties involving spectral sensitivity, radiant sensitivity, response time, noise level, ambient temperature sensitivity, etc. Among these, we are primarily interested in the spectral properties for purposes of this discussion. Besides the well-known vacuum and gas-filled diodes and the photomultipliers which are sensitive to ultraviolet and to visible light, there are many other detectors which are light and/or infrared sensitive. They are most often "solid-state" devices whose properties depend upon the choice of material from which they are made. Among the materials are cadmium sulfide and cadmium selenide for visible light and near-infrared, silicon, germanium and lead sulfide for longer-wave infrared, lead selenide, indium antimonide, gold-doped germanium and others whose spectral sensitivities extend increasingly further into the infrared. (The lower the target temperature, the greater the wavelength to which the detector must respond.)
Besides these, there is the traditional thermocouple detector in its various forms as well as diverse thermistor detectors and the newer pyroelectric detectors, the latter of which generate a voltage in response to a change in temperature.
A particular feature of our invention is that identical detector types are used, and the optical filters are eliminated by making the branched bundles leading to the detectors of suitably different optical glass. An example is given of the case of a lead sulfide detector whose spectral sensitivity at room temperature is illustrated in FIG. 2. The spectral transmittances of two representative types of glass, borosilicate glass A and quartz B, are shown in FIG. 3. When the lead sulfide detector is used with each of these glasses in turn, its spectral response is defined by the respective curves in FIG. 4.
We note that these curves have an overlapping area and do not occupy separate wavelength intervals, as is generally the case in two-wavelength radiometry. However, the theory of operation is nevertheless applicable, in an approximate way. One need only think of each of the curves as being replaced by a narrow spectral line at its centroid, and these lines identify, approximately, the two effective wavelengths of the system.
We consider, now, the case where the third fiber bundle is used for illuminating the target area in order to facilitate the aiming of the optical probe. It often happens that the illumination source which is used contains sufficient infrared radiation, within the spectral range of the detectors, to cause a "background level" which is superposed on any thermal signal from the target. In such a case, it is common practice to use the illumination source for initial positioning of the probe and then to turn it off when the actual measurements are being made.
In many cases, it would be desirable to leave the illumination source on during the measurements in order to ascertain that the probe was still in its proper position. For such cases, our solution is to make use of "cold light," from which the infrared content has been removed by optical filtering, and also to suppress any visible light response of the detectors by further optical filtering. The use of infrared-absorbing, visible light-transmitting filters is known in the art. These are typically either absorption-type or interference-type filters, often referred to as "heat absorbing" filters, which are used in slide projectors and the like. It is merely necessary to insert one of these anywhere in the optical path between the light source 20 and the remote or common end 11 of the illumination branch of the fiber bundle in order to achieve an aiming spot with minimal infrared content.
At the same time, the visible light response of the detectors may be suppressed by use of any of a variety of infrared-transmitting, visible, light-absorbing filters which are known to optical practitioners. Similarly, these may be introduced anywhere in the receiver optical path. In making the selection of both the above types of filters, care must be taken to ensure that their respective transmittance regions do not overlap.
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A band-ratio radiometer is disclosed which makes use of either a bifurcated or trifurcated fiber optic bundle, over two branches of which the sample radiation is transmitted in different wavelength regions. The third branch may be used to provide illumination of the target area, for aiming purposes, by injecting light at the near end of this branch. By this means, the remote ends of all three bundles may be focussed precisely upon the target area, with no parallax problem. The system avoids the use of conventional optical filters by making use of detectors which are identical in wavelength sensitivity and optical fibers which differ in wavelength transmittance.
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This application is a continuation-in-part of application Ser. No. 82,131, field Jun. 23, 1993, now abandoned, and of application Ser. No. 127,163, now U.S. Pat. No. 5,421,817, filed Sep. 27, 1993, each of which is a continuation-in-part of application Ser. No. 877,873, filed May 4, 1992, now abandoned, which is a continuation of application Ser. No. 703,610, filed May 21, 1991, now U.S. Pat. No. 5,109,847, the disclosures of which are all incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The invention of our prior application, now U.S. Pat. No. 5,109,847, generally relates to an apparatus that modulates the neurological responses associated with certain biological dysfunctions, neural pain, and pain caused by blood flow deficiency. More specifically, it is an apparatus and system for the treatment of selected pain and/or neural dysfunction-induced maladies.
The present relates to improvements thereof; more specifically, an apparatus for the topical iontophoretic administration of medication for the treatment of various conditions, and an apparatus for modulating neural responses using an additional modulation frequency.
2. The State of the Art
The sensation of pain is associated with numerous physiological and psychological ailments and is a universal experience of all complex living organisms. Pain, as the mental manifestation of a neurological response, is an important biological attribute and is critical to living and enabling a person to understand dangers in the environment and to adapt thereto. Concomitant with this important role, the alleviation of pain has been a fundamental goal of medicine and philosophy for as long as the medical profession has existed. Indeed, the ability to control the neurological pathways through which pain is conveyed has made complex procedures far simpler to implement and much less traumatic to the patient.
There is a class of neurological response which is associated with pain that does not correspond to or act as a warning for a particular physical damage or biological dysfunction. In fact, many biologically important transitions are characterized by significant pain, such as the withdrawal period of an addict, during which time the addict's system is depleted of a specific endogenous narcotic. Other mental conditions which are neurologically response-dependent conditions include depression, hypertension, causalgia pain, insomnia and jet lag. Analogous to pain being an indication that the local environment is being dangerous, occurrences such as jet lag and drug withdrawal are both essentially a severe change in a person's environment.
The importance of the ability to control neurological response and associated perceptions of pain and distress has led to the development of many pain control methodologies. The most common of which employs bio-active chemical agents that act to block neural transmission pathways within the body. These are designed to operate locally for spot treatment or broadly for generalized control or inhibition of pain response throughout the body. Chemical interference with pain signals has broad based appeal, but in many instances is unacceptable. For example, some chemicals have toxic side affects or cause allergic reactions to certain patients. For more chronic ailments, such as chronic migraine headache syndrome, repeated absorption of chemical narcotics may reduce the associated pain, but at unacceptably high costs associated with interference with routine activities, addiction, and/or toxicity of the narcotic.
In view of the problems associated with chemical pain control, efforts have abounded to discover treatment approaches which would not involve pharmacological (chemical) interference with neural transmitters in the body. One approach that has recently sparked tremendous interest is the use of low power electrical stimulator devices capable of passing currents across key neural transmitter junctions in the body and thus effecting a blockage of neurological pathways which are inducing messages of pain to the brain. A practical implementation of this approach is disclosed in U.S. Pat. No. 3,902,502 to Liss, et al; the teachings of which are herein incorporated by reference.
The system disclosed in the '502 patent presented a pulsed direct current waveform having a high frequency carrier modulated by a single low frequency modulation. It was discovered that this waveform was particularly successful at controlling symptoms of certain neurological disorders.
Although effective for its applied treatment, many electrical stimulatory devices are limited to certain applications and lack the requisite flexibility for broad-based appeal. In addition, a drawback to the use of electrical stimulation to control pain is the concern by patients and others about the impact of power dissipation on the patient. Although low current, the power dissipation of many of the electrical stimulation devices is still quite significant. Efforts to reduce the applied power have resulted in stimulation devices with little or no physiological impact.
There has been, therefore, a search for new electrical stimulation devices characterized by exceptional pain management capabilities while reducing the overall patient exposure to electrical energy.
It is also clear that pain can be caused by organic physiologic conditions, trauma, infections, and the like. While systemic analgesic agents have been used with some success, it is often desirable to attempt administration directly to the area of the patient where the medication is required. This concept also has application to the administration of a wide variety of pharmacological agents. For example, Joseph Kleinkort delivered a presentation almost a decade ago at the USAFE Medical Convention in Garmisch, Germany, in which he described to iontophoretic administration of hydrocortisone; the technique was referred to as transionic injection. Using two moistened electrodes and a particular type of micronized hydrocortisone dispersed in a petrolatum ointment base, it was found that transionic injection was as effective as percutaneous injection. The apparatus used by Kleinkort provided an electrical waveform to the electrodes which consisted of a carrier frequency of 12-20 KHz and a modulation frequency of 8-20 Hz.
More recently, Sibalis in U.S. Pat. No. 5,135,478, the disclosure of which is incorporated herein by reference, described an electrical transdermal drug applicator which provides a particular waveform to counteract the apparent decrease in the amount of the pharmaceutical delivered as the duty cycle of the apparatus increases (i.e., the time during which current is "on" relative to the time current is "off"). Sibalis provides a waveform to the electrodes which comprises a negative conditioning pulse and a sequence of different waveforms which dilate blood vessels, impede coagulation and vasoconstriction, and thereby allow for better transdermal delivery of the drug. The complex waveform generally uses an AC carrier frequency of 1.5-3.5 MHz, a pulse width of 1.25-11.25 ms, and is modulated by both an AC modulated :square wave at 250 Hz and a second AC modulator at 570-870 Hz.
There is yet a need for the improved transdermal delivery of drugs, including improved tissue wetting management, minimization of the amount of electrical energy delivered to the patient, improved patient response and comfort with the procedure, and there is especially a need to tailor the aspects of delivery with respect to the particular drug or combinations of drugs used.
SUMMARY AND OBJECTS OF THE PRESENT INVENTION
This invention may be summarized, at least in part with reference to its objects.
It is, therefore, an object of the present invention to provide an apparatus for the selective generation of low current nerve stimulation waveforms configured to control pain and/or reduce the symptoms of certain neurological dysfunctions..
It is another object of the present invention to provide an apparatus for generating a complex waveform that when applied to a patient involves very low power dissipation.
It is a further object of the present invention to provide a pain control system that includes a means for creating a complex waveform and a data processing means for managing and recording the implementation of that waveform.
It is yet another object of the present invention to provide a method for low power, electrically induced analgesic treatment by the placement of at least two electrodes on selected neurologically important sites and the controlled introduction of a complex waveform for a predetermined time forming a treatment regimen.
It is still another object of the present invention to provide a method for treating the neurological dysfunctions associated with such ailments as migraine headaches, dental procedures, PMS and drug withdrawal.
The above and other objects of the present invention are realized in a specific illustrative electrical stimulator device. This device includes a small DC power source and a means for converting the current output of the power source into a complex waveform as an output across two or more electrodes attached to the patient's body. The complex waveform includes a carrier frequency with at least two low frequency modulations. The carrier frequency will range between 1 KHz and 300 GHz. The first modulation to this carrier wave will have a frequency between 0.01 and 199 kilohertz (i.e., between 10 Hz and 199 KHz). The second modulation to the carrier will have a frequency range between 0.1 and 300 kilohertz (i.e., between 100 Hz and 300 KHz). An optional third modulation to the carrier will have a frequency in the range between about 0.1 and 1,000 Hz. Each modulation to the carrier is preferably a pulse train in the form of a square waveform.
The placement of the electrodes will depend on the ailment of the subject of treatment, and the frequency of treatment will depend on the severity of the pain or dysfunction.
In accordance with the varying aspects of the present invention, the stimulator device may include a digital delta processor and stored programming for enhanced implementation of the prescribed treatment. In this manner, the program controlling the output of the stimulator will prevent use beyond a number of times and beyond the time set for each use. The limits of number of uses and of length of time for each use will be set by the prescribing physician. This promotes and enhances the use of expressly developed treatment regimens by a prescribing physician. The patient's progress can be compared to patient compliance in the context of continuing the prescription or altering same on behalf of the patient.
In our improved invention, one object is to provide an improved tissue-electrode interfacial environment to provide the transdermal delivery of the pharmaceutical agent.
Another object of our invention is to minimize the amount of electrical energy which must be applied to the patient to enable a suitable dosage of the drug to be administered.
Yet another object of the invention is to avoid harsh sensation response to the electrical energy, thereby improving patient comfort and compliance with the procedure.
Still another object of the invention is to tailor the characteristics of the electrical energy to the particular drug being administered to the patient to enhance the administration and/or the efficacy of the drug delivered.
In particular, the present invention also provides an improved apparatus which comprises the aforementioned electrical stimulator device having two moist electrodes, at least one of which is contains a pharmaceutical agent in a suitable carrier. The complex waveform used during iontophoretic transdermal administration includes a carrier signal operating at 1-300 KHz, a first modulating frequency operating at 0.01-199 KHz (10-99,000 Hz), and a second modulation frequency operating at 0.1-300 KHz (100-300,000 Hz). The waveform is preferably monopolar, or at least is essentially monopolar in order to provide a net electrophoretic driving force for diffusion of the pharmaceutical agent into the patient.
The foregoing features of the present invention may be more fully understood in view of the illustrative description presented below and the claims.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1A-1E are representations of sample carrier, modulation, and composite waveforms utilized in the present invention;
FIG. 2 is a block diagram of the inventive apparatus for generating the waveform depicted in FIG. 1; and
FIG. 3 is a logic flow chart of the data processing program controlling the operation of the apparatus of FIG. 2.
FIG. 4 is a chart of the effect of the inventive apparatus on certain neurotransmitters.
DESCRIPTION OF PREFERRED EMBODIMENTS
Discussing the present invention first in overview, it is a fundamental diserratum to provide a portable non-invasive analgesia inducing apparatus that exhibits a selectively developed complex waveform of electrical output. This output is applied between at least two contact probes for generating intracorporal current. The placement of the probes will depend on the treatment regimen. For example, migraine headache syndrome may involve the placement of the contacting probes on each side of the patient's cranium, one at the primary site of pain and the second at the contralateral trapezius insertion. Other locations may include intraoral, e.g., for local analgesia to control the pain associated with a dental restoration procedure.
Although the theory describing the underlying pain control phenomenon is not well known or, for that matter, even established, and while not desirous of being constrained to a particular theory, it is generally believed that the introduction of an intracorporal current acts upon the electrically conducted neural transmitters of the patient. It has been discovered that the particular complex waveform of the present invention when applied to a patient creates distinct changes in the blood plasma and cerebral spinal fluid concentration of such compounds as melatonin, serotonin, beta endorphin, norepinephrine and cholinesterase which are highly correlated with the pain/pleasure centers of the central nervous system.
In operation, the present invention involves two functional attributes. The first involves the generation of the complex waveform of a select signature. The second attribute is directed to the implementation of the treatment in a delineated treatment regimen.
With the above overview in mind, attention is first directed to FIG. 1 which presents the various components of the complex waveform of the present invention. More particularly, and starting with FIG. 1A, a graphical representation is provided of the carrier frequency for one specific time segment. In this representation, the carrier frequency equals 15 kilohertz. The amplitude is 40.0 volts peak max (DC) with a duty cycle of 50%. The waveform contains 25 bursts of 15 pulses for each burst. The period for each burst is 2 milliseconds and the period for each pulse is 66.7 microseconds. For each, the burst and the pulse, the duty cycle is 50% on time. Continuing, FIG. 1B presents the first modulation to the carrier frequency. In this example, the first modulation has a frequency of 15 Hertz and a duty cycle of 75%. The second modulation is depicted in FIG. 1C. The second modulation has a frequency of 500 Hertz and a 50% duty cycle. Continuing through FIG. 1D, the complex waveform combining the components depicted in FIGS. 1A through 1C are presented.
The complex waveforms of the present invention may be generated with sinusoidal, sawtooth, hyperbolic or other wave shapes; for simplicity and clarity, the waveforms presented in FIGS. 1A through 1E and further discussed below have been exemplified by simple square waves.
A cycle for the waveform will consist of 50 milliseconds "on" time, in which the pulses for that frequency combination are generated, and an "off" time of 16.7 milliseconds.
Finally, in FIG. 1E, a complex waveform according to the present invention is provided, in which the polarity of the output is switched from positive to negative on a periodic basis, e.g., 67 milliseconds. This is contrasted with the waveform of FIG. 1D in which the polarity remains positive throughout the cycle; the pulsed DC waveform of FIG. 1D is considered a monopolar output while the output depicted in FIG. 1E is considered bipolar.
For purposes of rough approximation, the energy dissipation in using the present invention is represented by the area under the pulses depicted in FIG. 1D. It can, therefore, be recognized that by adding the second modulation, having a 50% duty cycle, results in a 50% decrease in power dissipation.
The circuit is presently provided with one of the following frequency combinations, but is not limited to:
1) 15 Hz, 500 Hz, 15,000 Hz--Monopolar;
2) 15 Hz, 500 Hz, 15,000 Hz--Bipolar (7.5 Hz);
3) 15 Hz, 500 Hz, 60,000 Hz--Monopolar; or
4) 15 Hz, 4,000 Hz, 60,000 Hz--Monopolar.
As noted above, the invention provides an optional third modulation of the carrier wave having a frequency range of 0.1 Hz to 1,000 Hz, more preferably 1-50 Hz, and most preferably 5-25 Hz. In this embodiment, preferred complex waveforms are derived from the following components: a carrier frequency of 1 KHz to 300 GHz, preferably 100 MHz to 200 GHz, more preferably 20-100 GHz, and most preferably 50-75 GHz; a first modulation frequency of 10-1000 Hz, most preferably 500±50 Hz; a second modulation frequency of about 15 KHz±5 KHz, more preferably ±3 KHz, and most preferably ±2 KHz; and a third modulation frequency in the range of 1-50 Hz, most preferably 15±5 Hz. The present invention can thus be generally described as generating an n-modulated complex waveform.
Turning now to FIG. 2, the functional elements of the inventive device are presented. The power source to the present system will either be a battery having nominal 9 volt terminal voltage or some rectified and properly transformed line (AC) power source. The battery provides the basic DC power source for generating the complex waveform. This is channeled and controlled by the voltage multiplier, 20. The output of the voltage multiplier 20 which is between 27 v to 40 v, is fed to signal generating circuit 60 which is the oscillating circuit that converts the constant DC output into the complex waveform having the desired characteristics.
The specific constant current and current limited waveform generated by signal generating circuit 60 is pre-set by entering the various frequency settings for the two modulations, and the carrier. This may be entered manually through adjusting the settings on control panel 90. Alternatively, these settings may be stored in digital memory 40 as previously set values. The actual output of this system is regulated by monitor 70 which then provides the system output on a display, via control panel 90, or a memory value for subsequent retrieval from memory 40.
The signal generating circuit 60 receives the voltage of 27 v to 40 v from the voltage multiplier. Within the signal generating circuit 60, the voltage branches off into a carrier frequency and two modulation frequencies. An example of the branching of the waveform is depicted in FIGS. 1A-1C.
In FIG. 2, the system supports two separate probes for placement on the patient. Probe 63 represents the positive terminal as generated by signal generating 60. The second probe 65, is grounded within the circuit. For operation applying a bipolar waveform, the probes are connected to terminals 65 and 68, respectively. Terminal 68 is the output from reversing circuit 50, which may be present and which acts to flip the signal generating circuit pursuant to pre-set timing constraints.
The following ancillary systems are also present in this circuit. The low battery and system on indicator 10 which monitors the battery output via voltage multiplier 20 generates an alarm signal when battery output voltage drops below the preset limit, say 7.0 volts. It also shuts the system down if the battery voltage falls below the preset limit of approximately 6.0 volts.
The analog/digital converter 92 converts the signal from the signal generating circuit 60 so that the patient can read it. The analog/digital converter 92 reads the level of output and converts it to the appropriate signal for the four gate integrated circuit which uses that signal to turn on the appropriate sequence of four LEDs 110.
Finally the impedance detector 160 is used to determine if the system is being used on a person (as opposed to someone just running the system without attaching it to a person).
FIG. 3 depicts an exemplary flow chart of the timer unit 90 which the apparatus will use to monitor usage by the patient. A computer program embodying the protocol shown in the flow chart operating in combination with the present invention will prevent the patient from misusing the apparatus, and will allow the physician to set an individual treatment program and to monitor the patient's compliance to the set program.
The timer unit 90 will allow the therapist to set the number of days the system is to be used, the number of times per day the system will be used, and the time duration for each use.
The program will start 800 with an Origination Decision module 810. The Origination Decision Module 810 will give the therapist three choices for use. If the Individualized Program 820 pathway is chosen, the timer unit will load the Individualized Program 820. Then the Individualized Program will begin with a display showing the Current Setting 900, for each of the parameters (i.e. the number of days of use, the number of times per day of use and the length of time for each use). Next the program will ask the therapist whether he wants to Keep the Current Settings 900, or Input New Settings 830. If the therapist wishes to use the same settings as are already registered in the program, the Individualized Program 820, will Store 860 the values and will End 840. However, if the therapist wishes to change the settings, the program will proceed to the Change Input Values 850 module in which the computer will ask the therapist for the new values for the settings. Then the computer will Store 860 the new values and will End 840.
Another selection which a therapist may make at the Origination Decision Module 810 is to read the stored information from the patient's system. If the therapist decides to access the Read Stored Results 865 module,the Setting and Use information will be displayed 870, and the therapist will decide whether to store the patient information in the Patient Storage Module 880, or else it will Dump the information 890 and it will End 840.
A final selection which the therapist may access through the Origination Decision Module 910, is actually to use the system. If this choice is the inputted selection, the Run Timed Program 910 will be initialized. The Run Timed Program 890 will read the stored 860 values. Then the program will Check 920 the Stored 860 values against the Current Running Settings 900 which is the values of the Run Timed Program 890 for this usage of the system. If the Current Running Settings 900 for the number of days of use is greater than the Stored 860 values, the program will End 840 without the system being turned on. Next, the Run Timed Program 890 will check the value of the Stored 890 values for the number of uses for a given day and if the Current Running Settings 900 is greater than the Stored 890 values for number of uses for a day, the system will End 840 for that day and the system will not be able to be used until the next day. Finally, as the system is being used, a Running Time Clock will be compared to the Run Timed Program, 890, and when the Current Running Settings in 900 is greater than the Stored 890 values for the length of time for that session, the system will End 840 for that session and the system will not be able to be used until the next session period.
The chart depicted in FIG. 4 demonstrates the effects on the ACTH, cortisol, beta endorphin and serotonin, biochemical neurotransmitter concentrations of patients having been treated with the inventive apparatus having two modulation frequencies. Multiple tests were made on three normals and other normal volunteers using monopolar, bipolar, and placebo instruments on a double blind basis. The symbol "n" denotes how many samples were made for each type of test. All tests for two of the three normals were made at the same time of day, the third normal was done always at 8 a.m. each morning and the 10 volunteers were processed at 10 a.m. to 12 noon for all their testing.
As is shown in the chart, the results on the tested neurotransmitters were marked. In each, the bipolar application had the greater effect on the neurotransmitter, with the monopolar still having significant results in its own right.
Turning to the improved invention relating to iontophoretic transdermal delivery, the present invention, most preferably with two modulating frequencies, is applicable to the topical delivery of virtually any pharmaceutical agent which has a charge or can be formulated in a carrier such that the molecule has a charge or a dipole. As is commonly known in techniques which use electrokinetic phenomena, such as electrophoresis and electroosmosis, a charged species will tend to migrate in a medium depending on the relationship of the average charge (i.e., positive or negative) on the species to the charge applied to the liquid medium in which the species is present in solution. For example, when it is desirable to use a certain drug having a negative charge, the drug in an appropriate carrier is applied topically to the area to be treated and the negative electrode (of the foregoing apparatus) is applied in contact with the same patient area. Because the negatively charged drug will be repelled by the negative electrode, the drug will migrate away from the electrode, and thus transdermally into the patient's tissues.
It is important to note that the present invention, when used for iontophoretic delivery, provides a waveform which is preferably exclusively monopolar. This arrangement is in contrast to the teachings of the prior art, such as Sibalis, which teach the use of alternating current. We have found that the use of a monopolar waveform, such as that shown in FIG. 1D, provides improved transdermal deliver by virtue of the avoidance of a reversal in polarity which will tend to reverse or slow the transdermal delivery of the drug. Additionally, the use of a monopolar complex waveform allows for reduced electrical energy to be applied to the patient to achieve a particular dosage; especially since additional energy is not required to compensate for the application of an alternating current waveform which impedes the transdermal delivery. While not preferred, it may be desirable in some situations to provide a waveform that is essentially monopolar, that is, a bipolar waveform in which one polarity dominates (is present for a longer period of time) the reverse polarity; of course, the dominant polarity is that which is effective in delivering the pharmaceutical agent to the patient.
The present invention is applicable to the delivery of a wide variety of pharmaceutically active agents, including anti-inflammatory agents like hydrocortisone, proteins and/or hormones such as insulin, nicotine, antianginal and/or vasodilator compounds such as nitroglycerin, vitamins and cofactors such as nicotinic acid, antihypertensives such as propranolol, and anesthetics such as lidocaine, some of which are commonly used in transdermal patches and other topically-applied compositions. By the term "topical" is meant the direct iontophoretic administration of the pharmaceutical agent, whether on the surface of the skin (dermis), eye, gum, or anywhere on the body on which electrodes can be conveniently located.
The present invention also has significant use in the iontophoretic delivery of psychoactive and neuroactive agents. As described previously and shown in FIG. 4, the neuroaugmentive apparatus of this invention can increase the levels of serotonin, beta-endorphin, GABA, and other neural transmitters and controlling molecules. Accordingly, the administration of an analgesic, if not a psychoactive or neuroactive agent, can be further enhanced by the synergistic increase in such neurotransmitters.
When the apparatus is used for iontophoretic delivery, a monopolar signal is more preferred. The carrier frequency (e.g., as shown in FIG. 1A) ranges from about 1 Hz to about 300 KHz, and facilitates the penetration of the total electrical signal; more preferably the carrier signal ranges from about 10 Hz to about 100 KHz, and most preferably ranges from 10-50 KHz. The first modulating signal is the "bio-active" frequency which, without desirous of being constrained to any particular theory, is believed to enhance the neurobiochemical levels in both the cerebral spinal fluid and in the blood plasma, such as by altering the permeability of synapses and other cellular membranes to various ions. This first modulating signal ranges from about 10 Hz to about 199 KHz, more preferably from about 10 Hz to about 50 KHz, and most preferably is in the range of 10-100 Hz. The second modulating signal is analogous to a "tuning" frequency and can be used to reduce the aggregate energy delivered to the patient during the "on" portion of the duty cycle. The second modulator ranges from 100 Hz to 300 KHz, more preferably from 100 Hz to 100 KHz, and most preferably in the range of 100-1,000 Hz. A preferred embodiment of the iontophoretic delivery device uses a carrier signal of about 15 Khz, a first modulator of about 10 Hz, and a second modulator of about 500 Hz.
The particular drug or combination of drugs to be administered is provided in a suitable carrier by methods well-known to the artisan. It is preferable to formulate a solution, gel, or mixture of the drug for delivery through moist electrodes which are commonly used and available, and analogous to those described by Sibalis. It is also preferable to use a chemical penetration enhancer, such as DMSO (dimethyl sulfoxide), to assist in diffusion of the pharmaceutical agent into the patient's tissues.
The embodiment of the above description has been based on discrete components to enhance the understanding of the functional characteristics of the system. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention.
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The present invention pertains to a portable non-invasive electronic apparatus which can be used to relieve pain or alter the symptoms of certain neurological dysfunctions. A specifically contoured constant current and current limited waveform is generated and applied to selectively positioned electrodes. A program controlled processor tracks usage of the unit to prevent abuse and monitor progress. An overall treatment regimen centered on the stimulator may be effected simply and safely. The invention also provides an apparatus and method for the iontophoretic topical administration of a pharmaceutical agent. The apparatus is operated in a monopolar mode with a particular complex waveform which synergistically enhances the amount of various neurobiochemical species in the cerebral spinal fluid and the blood plasma.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an inverter circuit and in particular to an improved inverter circuit capable of providing highly stable output signals. The present invention has a particular applicability to a buffer circuit for integrated circuit devices.
2. Description of the Prior Art
Referring to FIG. 1, a typical prior art semiconductor integrated circuit device (hereinafter referred to as a IC device) is shown connected to a device for testing the same. Specifically, the IC device 10 to be tested is connected to an IC tester 30 via a performance board 20. The IC device includes an input buffer 11 for receiving test data signals and test enable signals T E from the IC tester 30, an inner circuit 13 for processing test data, and an output buffer 12 for transferring signals from the inner circuit 13 as outputs. The IC tester 30 contains a comparator circuit 32 to be connected to the IC device to receive outputs signals therefrom representing the test results, and a DC source 33. Supply voltage V DD from the DC source 33 is applied to the IC device 10 through the performance board 20.
In FIG. 2, there is illustrated a prior art output buffer circuit for the IC device which comprises a pair of inverters. The output buffer circuit 12 includes CMOS inverters I 1 and I 2 . One inverter I 1 comprises a P-channel MOS field effect transistor (hereinafter referred to as FET) 1 and a N-channel MOSFET 2 which are connected in series between the supply voltage V DD and ground potential GND. The FETs 1 and 2 have their gates connected together to receive input voltage signals V IN . The other inverter I 2 also includes a P-channel MOSFET 3 and a N-channel MOSFET 4. The gates of the MOSFETs 3 and 4 are conencted to a junction node N 1 between FETs 1 and 2. A junction node N 2 between the FETs 3 and 4 constitutes an output terminal for the output buffer circuit from which output voltage signals V OUT are supplied.
In FIG. 3, there is illustrated a timing diagram for input and output voltage signals associated with the output buffer circuit 12. In operation, when the input voltage V IN changes from a low "L" level to a high "H" level at a time t 1 , the high level voltage "H" is applied to the gates of the FETs 1 and 2, thereby rendering the FET 1 non-conductive and the FET 2 conductive. As a result, the high level voltage V 3 at the node N 1 starts falling off upon the lapse of the delay time provided by the CMOS inverter I 1 after time t 1 , and it settles down to the "L" level through a predetermined time interval. As the voltage V 3 on the node N 1 drops to the "L" level, the FET 3 is driven conductive, while the FET 4 is driven non-conductive. Consequently, the low level output voltage V OUT at the node N 2 starts to rise upon the lapse of the delay time provide by the CMOS inverter I 2 after the voltage V 3 at the node N 1 has dropped to the "L" level, and at time t 3 the output signal V OUT reaches the "H" level.
When the input signal V IN shifts from the "H" level down to the "L" level at t 4 , the FET 1 is turned on while the FET 2 is turned off. Then the voltage V 3 at the node N 1 begins rising upon the passage of the delay time defined by the CMOS inverter after t 4 , and it reaches the "H" level through a predetermined time. Upon the voltage V 3 at the node N 1 assuming the "H" level, the FET 3 is rendered conductive while the FET 4 is rendered non-conductive. The output signal V OUT at the node N 1 begins falling at t 5 when the delay time provided by the CMOS inverter I 2 has lapsed after the voltage V 3 on the node N 1 shifted up to the "H" level. At t 6 , the output signal V OUT goes down to the "L" level.
As can be seen in FIG. 3, with the input buffer circuit shown, undesirable undershoot or ringing are caused in the output waveform as the output signal V OUT falls off during the time interval t 5 -t 6 . However, no overshoot and ringing are witnessed as the output signal V OUT goes up during the time interval between t 2 and t 3 . The reason for this is as follows.
The time interval t 5 -t 6 during which the output signal V OUT drops from "H" level to the "L" level is relatively short, resulting in a steep downhill slope in the output waveform as shown in FIG. 3. On the other hand, the time interval t 2 -t 3 during which the output signal V OUT rises from the "L" level to the "H" level is relatively long, forming a gentle uphill slope in the output waveform. The rise and fall times of the output waveform are determined by the time it takes for the output capacitance C o (including a stray capacitance of the inverter and an input capacitance of an external circuit connected to receive the V OUT ) to be charged and discharged. The charging and discharging times of the output capacitance C o is proportional to the product of the value of the output capacitance C o and the on-resistance of the the FETs 3 or 4. Assuming that the output capacitance is fixed, the rise time t 2 -t 3 and the fall time t 5 -t 6 of the CMOS inverter I 2 is determined by the on-resistances of the FETs 3 and 4. It should be noted here that, the transistor size being the same, the on-resistance of the FET 3 is larger than that of the FET 4. This is because the high P-channel FET 3 has a small mobility than the N-channel FET 4.
Due to the above-mentioned fact that the on-resistance for the P-channel FET 3 is larger than that of the N-channel FET 4, the charging time (equal to t 2 -t 3 of FIG. 3) of the output capacitance C o by the output signal V OUT rising from the "L" level to the "H" level is longer than the fall time t 5 -t 6 of the output signal V OUT or the discharge time of the output capacitor C o where the output voltage VF OUT drops from the "H" level to the "L" level. In short, the rise time of the output signal V OUT is longer than the fall time of the output signal. Phrased differently, the output signal V OUT increases gradually and gently and decreases rapidly and sharply.
Connected to the output of the output buffer is inductance included in the package and the external electrical interconnections as well as the above stated output capacitance C o . Since the impedance of the input buffer is not matched with the external impedance, undershoot and ringing are caused in the output waveform as the output signal V OUT drops to the "L" level. The undershoot and ringing in turn lead to an erroneous operation of externally connected devices.
The IC device 10 having the input buffer circuit 12 of FIG. 1 incorporate therein tends to suffer some problems when put to test procedures. For example, components used to connect the IC device to the IC tester such as IC sockets and the performance board as well as the electrical interconnections within the tester have their own distributed inductances as indicated by the reference numeral 14, 21 and 31 in FIG. 1. These inductances bring about a change in the supply voltage in the IC tester 30 whenever the supply current undergoes a transient change. On the other hand, the logic level of the inputs supplied from the IC tester into the IC device is determined based on the common ground potential GND as a reference voltage. Thus, if the fluctuating supply voltage V DD and GND in the IC tester 30 are transferred into the IC device, the threshold values of the P- and N-channel FETs 1-4 are caused to shift, giving rise to the aforementioned undershoot and ringing. This in turn disturbs the normal test procedures of the IC device.
One prior art of particular interest to this invention is disclosed in a paper by T. Wong et al. entitled, "A High Performance 129k Gate MOS Array". The paper describes two pairs of P- and N-channel MOSFETs which are connected in series between a supply voltage and a ground potential.
SUMMARY OF THE INVENTION
One object of the invention is to provide an inverter capable of providing highly stable output signals.
Another object of the invention is to prevent undesirable undershoot and ringing in the output signals produced by an inverter circuit.
Still another object of the invention is to stabilize the outputs signals produced by an IC device.
Still another object of the invention is to prevent undershoot and ringing in the output signals produced by an IC device.
Still another object of the invention is to obtain output signal from an IC device under testing procedures accurately and exactly representing the test results.
Still another object of the invention is to stabilize the supply voltage of an IC tester used in the test procedures of IC devices.
Briefly stated, an inverter circuit of the invention includes a first FET of one conductivity type and a second FET of the other conductivity type which are connected between a supply voltage and a ground potential. The inverter circuit also includes a delay circuit for delaying input signals under control of a signal for designating a predetermined operating mode. The first FET has its control electrode connected to receive the input signals, and the second FET has its control electrode connected to receive the output signals after they have been delayed by the delay circuit. The second FET has an on-resistance lower than the first FET. Output signals are provided at the junction between the first and second FETs.
In a predetermined mode of operation, the first FET functions in response to the input signals, while the second FET in response to the input signals delayed by the delay circuit. Though the second FET has an on-resistance smaller than the first FET, it is turned on in response to the delayed input signal, thereby preventing a sharp change in the output signal.
In a preferred embodiment of the invention, the delay circuit comprises a third FET of the opposite conductivity type connected to the control electrode of the second FET. The second FET has its control electrode connected to receive the input signals through the third FET. In a predetermined mode of operation, the threshold voltage of the second FET rises in response to a changing level of the input signal. As a result, the conducting timing of the third FET is correspondingly delayed, causing the input signal to be applied to the control electrode of the second FET through the third FET with a time delay.
In another preferred embodiment of the invention, the inverter circuit may be incorporated into the output buffer circuit of an IC device having a testing mode of operation. With the inverter circuit of the invention incorporated, the IC device in the testing mode generates output signals exactly representing the test results.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration showing an interconnection between a typical semiconductor integrated circuit device and a device for testing the performance of the integrated circuit device;
FIG. 2 is a circuit diagram of a conventional output buffer circuit;
FIG. 3 is a timing diagram for input and output signals associated with the output buffer circuit of FIG. 2;
FIG. 4A is a schematic illustration showing an interconnection between a semiconductor integrated circuit device having incorporated therein an inverter circuit according to the invention and a testing device for testing the performance of the integrated circuit device;
FIG. 4B is a circuit diagram of the output buffer shown in FIG. 4A; and
FIGS. 5A and 5B are timing diagrams for the output buffer of FIG. 4B.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 4A, there are illustrated a novel IC device 10 and an IC tester 30 connected to each other for testing the performance of the IC device. A novel feature of the IC device 10 shown in FIG. 4A which distinguishes itself from the prior-art IC device of FIG. 1 is that the IC device 10 includes improved output buffers 15. The output buffers 15 are connected to be supplied with test enable signals T E from the IC tester 30. Otherwise, the arrangement of FIG. 4A is identical to that of FIG. 1, and no further description is given.
Referring to FIG. 4B, there is shown a circuit configuration of one output buffer circuit of FIG. 4A. In contrast to the prior-art output buffer circuit shown in FIG. 2, the output buffer circuit of FIG. 4B includes additional P-channel MOSFET 5 and N-channel MOSFET 6 provided in the inverter T 3 . The FETs 5 and 6 are connected parallel to each other between a node N 3 in communication with the gate of the FET 3 and a node N 4 in communication with the gate of the FET 4. The gates of the FETs 5 and 6 are connected together to receive test enable signals T E which are supplied by a test signal generating circuit (not shown). In normal operation, the test enable signal T E is of "L" level, and in the testing mode of operation the signal T E is of "H" level. The node N 3 is in communciation with the output node N 1 of the inverter I 1 . Otherwise the circuit configuration of FIG. 4B is generally identical to that of FIG. 2, and no further desription is given.
Now to describe the operation of the illustrated output buffer circuit in normal operating mode where the test enable signal T E is at the "L" level with reference to FIG. 5A. In FIG. 5A, there is shown a timing diagram for the output signal V IN , the voltage V 3 at the node N 3 , the voltage V 4 at the node N 4 and the output signal V OUT during the normal operation of the output buffer circuit. In the normal operating mode, the test enable signal T E is kept at the "L" level with one FET conducting and the other FET non-conducting. Under the conditions, as the input signal V IN shifts from the "L" level to the "H" level at time t 1 , the "H" level voltage is applied to the gates of the FETs 1 and 2, thereby rendering the FET 1 non-conductive and the FET 2 conductive. Consequently, the voltage V 3 at the node N 3 starts to fall off from the "H" level to the "L" level at t 2 when a predetermined delay time defined by the CMOS inverter I 1 has elapsed after t 1 , and it finally settles down to the "L" level at t 3 . The application of this low level potential to the gate of the FET 3 drives the FET into conduction.
On the other hand, when the voltage V 3 of the node N 3 reaches the threshold voltage of the FET 5, this potential change is transmitted through the conducting FETs to the node N 4 , bringing the voltage V 4 at the node N 4 from the "H" level to the "L" level at t 5 . As the voltage V 4 at the node N 4 falls below the threshold voltage of the FET 4 during the time interval t 3 -t 5 , the FET 4 is rendered non-conducting. When this happens, the "H" level output signal V OUT at the node N 4 start rising at t 4 upon the passage of the delay time provided by the CMOS inverter I 2 and reaches the "H" level at t 6 .
Then a t 7 the input signal V IN shifts from the "H" level to the "L" level, causing the FET 1 to be conductive and the FET 2 to be non-conductive. The voltage V 3 at the node N 3 begins to rise from the "L" level at t 8 upon the lapse of the delay time provided by the CMOS inverter I 1 subsequent to t 7 and it reaches to the "H" level at t 9 . This high level voltage V 3 is applied to the gate of the FET 3, driving the FET 3 non-conductive.
On the other hand, the voltage V 3 at the node N 3 rises to the level of the threshold voltage of the FET 5, this potential change is transmitted through the presently conducting FET 5 to the node N 4 , bringing the voltage V 4 on the node N 4 upward from the "L" level to the "H" level at t 10 . As the voltage V 4 at the node N 4 rises above the threshold voltage of the FET 4 during the time interval t 9 -t 10 , the FET 4 is rendered conductive. As a result, the output signal V OUT at the node N 2 begins to fall at t 11 when the delay time provided by the CMOS inverter I 2 has passed, and it reaches the "L" level at t 12 .
Now to compare the time interval t 3 -t 5 during which the voltage V 4 at the node N 4 drops from the "H" level to the "L" level and the time interval t 9 -t 10 through which the same voltage goes from the "L" level up to the "H" level, it will be readily seen in FIG. 5A that the falling interval t 3 -t 5 is longer than the rising interval t 9 -t 10 . The reason for this is as follows. The P-channel MOSFET 5 is of such characteristic that its threshold voltage decreases as the source-bulk voltage decreases. In a situation where the voltage V 3 at the node N 3 shifts from the "H" level down to the "L" level, a decrease in the voltage V 3 at the node N 3 , thus in the source voltage brings about a corresponding reduction in the threshold voltage of the FET 5. Consequently, it takes longer for the drain voltage V 4 to shift from the "H" level down to the "L" level than for the source voltage to shift from the "H" level down to the "L" level. In a situation where the voltage V 3 at the node N 3 shifts from the "L" level up to the "H" level, the time required for the voltage V 4 at the node N 4 to rise from the "L" level to the "H" level is not so long as the time for the voltage V 4 to fall from the "H" level to the "L" level in the situation stated above.
As described hereinabove, in the normal mode of operation, as the voltage V 3 at the node N 3 undergoes a change from the "H" level to the "L" level, the voltage V 4 applied to the gate of the FET 4 by means of the P-channel MOSFET 5 increases gradually, driving the FET 4 slowly into a non-conductive state. The result is that the rising waveform of the output signal V OUT is more gentle than in the prior art.
Now to describe the operation of the output buffer circuit during a test mode where the test enable signal T E is at the "H" level. Referring to FIG. 5B, there is illustrated a timing diagram for the output signal V IN , the voltage V 3 at the node N 3 , the voltage V 4 at the node N 4 and the output signal V OUT in the testing mode of operation. With the application of the "H" level test enable signal T E , the FET 6 is made conductive, while the FET 5 is made nonconductive. During the time interval t 1 -t 3 , procedures similar in the normal mode of operation take place. Thus, when the input signal V IN shifts from the "L" level to the "H" level at t 1 , the voltage V 3 at the node N 3 starts dropping from the "H" level to the "L" level at t 2 subsequent to the lapse of the delay time defined by the CMOS inverter I 1 , and it reaches to the "L" level at t 3 . This low level voltage is applied to the gate of the FET 3, rendering the FET 3 conductive.
On the other hand, as the voltage V 3 at the node N 3 falls to the level of the threshold voltage of the FET 6, the voltage change is transmitted through presently conducting FET 6 to the node N 4 , bringing the voltage V 4 at the node N 4 from the "H" level down to the "L" level at t 4 . As the voltage V 4 at the node N 4 falls below the threshold voltage of the FET 4 during the time interval t 3 -t 4 , the FET 4 is driven nonconductive. Then the low level output signal V OUT at the node N 2 starts to go up toward the "H" level at t 5 subsequent to the passage of the delay time defined by the CMOS inverter I 2 , and it reaches the "H" level at t 6 .
Next, when the input signal V IN shifts from the "H" level to the "L" level at t 7 as in the normal operation mode, the voltage V 3 at the node N 3 begins rising from the "L" level to the "H" level at t 8 upon the lapse of the delay time defined by the CMOS inverter I 1 , and it reaches the "H" level at t 9 . Consequently, the high level voltage is applied to the gate of the FET 3, driving the FET 3 nonconductive.
On the other hand, as the voltage V 3 at the node N 3 rises to the level of the threshold voltage of the FET 6, the change of potential is transmitted through the FET 6 to the node N 4 . This in turn causes the voltage V 4 at the node N 4 to rise from the "L" level and reach the "H" level at t 11 . During the time interval t 9 -t 11 , when the voltage V 4 at the node N 4 drops below the threshold voltage of the FET 4, the FET 4 is driven into conduction. In consequence, the high level output signal V OUT at the node N 2 starts to fall at t 10 subsequent to the lapse of the delay time provided by the CMOS inverter I 2 , and it attains the "L" level at t 12 .
In comparing the time interval t 3 -t 4 during which the voltage V 4 at the node N 4 falls from the "H" level to the "L" level with the time interval t 9 -t 11 where the voltage V 4 rises from the "L" level to the "H" level, it is obvious from FIG. 5B that the rising time interval t 9 -t 11 is longer than the falling time interval t 3 -t 4 . This is chiefly because of the fact that the threshold voltage of the N-channel MOSFET 6 increases as its source to bulk voltage increases. Thus, in a situation where the voltage V 3 at the node N 3 shifts from the "L" level to the "H" level, the threshold voltage of the FET 6 increases as the voltage of the node N 3 , thus of the source voltage increases. As a result, it takes longer for the drain voltage to shift from the "L" level to the "H" level than for the source voltage to shift from the "L" level to the "H" level. In contrast, in a situation where the voltage V 3 at the node N 3 changes from the "H" level to the "L" level, the length of time required for the voltage V 4 at the node N 4 to switch from the "H" level to the "L" level is not so long as in the aforementioned situation.
As has been described, while the voltage V 3 at the node N 3 switches from the "L" level to the "H" level during the testing mode, the potential V 4 applied to the gate of the FET 4 through the operation of the N-channel MOSFET 6 rises gradually, thereby driving the FET 4 slowly into conduction. The waveform of the falling output signal V OUT is more gentle than in the prior art as shown in FIG. 5B. The result is that undershoot and ringing during the time when the output signal falls off in the testing mode is eliminated or at least reduce to a minimum.
It should be pointed out here that the time required for the voltage V 4 at the node N 4 to rise to the "H" level during the testing mode is controlled by the length and width of the gate of the P-channel MOSFET 5. Accordingly, it is possible to adjust as desired the waveform of the falling output signal V OUT during the test mode by suitably selecting the gate length and width of the FET.
While the output buffer circuit comprising a pair of inverter circuits I 1 and I 2 has been described as a preferred embodiment of the invention, the present invention is applicable to an output buffer circuit comprising a single inverter circuit I 2 .
As is obvious from the foregoing description of the invention, since the output signal of the inverter circuit shown in FIG. 4B goes up gradually, undershoot and ringing are effectively prevented from occurring during the falling period of the output signal. In other words, the inverter circuit generates stable output signals.
When the inverter circuit of FIG. 4A is incorporated into the output buffer circuit of the IC circuit device shown in FIG. 4A, there is caused no undershoot or ringing in the output signal during the testing of the IC circuit device, contributing to the stabilization of the supply voltage in the IC tester employed to test the performance of the IC circuit device. Thus, the IC circuit device to be tested produces stable output signals accurately and exactly representing the test results.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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An inverter circuit (I 3 ) is disclosed which includes a P-channel MOSFET (3) and a N-channel MOSFET (4) connected in series between a power supply (V DD ) and a ground (GND). The inverter circuit further includes a P-channel MOSFET (5) and a N-channel MOSFET (6) connected in parallel between the gates of the FETs (3) and (4). The FETs (3) and (4) have their gates connected to receive testing mode signals (T E ). In a testing mode operation, the FET (6) is rendered conductive to allow an input signal to be applied to the gate of the FET (4) through the FET (6). The FET (4), having an on-resistance lower than the FET (3), is driven into conduction in response to the output signal applied through the FET (6), thereby providing a slowly rising output signal. The slow rising output signal is free from undershoot or ringing.
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BACKGROUND
[0001] The following disclosure relates to systems for buying and selling direct materials and stockable Maintenance, Repair and Operations (MRO) materials. “Direct materials” are raw materials and components used to manufacture products. “Stockable MRO materials” are replacement parts or spare parts for components, products, assemblies and subassemblies of capital equipment used by manufacturing companies. Some enterprises use electronic commerce (e-commerce) technology, such as e-selling and e-procurement applications, to buy and sell direct materials and stockable MRO materials. This buying and selling can occur in (a) B2B (Business to Business) scenarios where a single buying entity engages in e-commerce with a single selling entity, and (b) public or private trading exchange-based scenarios where multiple buying entities engage in e-commerce with multiple selling entities.
[0002] Both direct materials and stockable MRO materials are often modeled as internal part numbers (IPNs)(also called part identifiers, product numbers or product identifiers) in both buyers' and sellers' computer systems. An enterprise computer system's product lifecycle management (PLM) component may generate part numbers internally. Part numbers of direct and stockable MRO materials in behind-the-firewall (BTF) enterprise computer systems carry information that trigger enterprise and e-commerce system application logic, such as pricing, costing, planning, and inventory management. Internal part numbers generally have no inherent meaning outside of the firewall (OTF) of the enterprise systems landscape.
[0003] Outside the firewall (OTF) means outside an enterprise's computer security system. Inside the firewall (ITF) or Behind the Firewall (BTF) is inside an enterprise's computer security system.
[0004] A key obstacle in business-to-business (B-to-B or B2B) e-commerce in public and private sales and procurement exchanges (PTXs) is that participating purchasing and selling entities do not understand each other's product identifiers, i.e., part numbers. For example, a company that makes computers may use its own internal part number (IPN) for a part to be purchased. A supplying manufacturer may have a Manufacturers Part Number (MPN) for a form, fit, function equivalent part. A supplying distributor may have its own Vendor Part Number (VPN) for a form, fit, function equivalent part. Use of heterogeneous, independently generated product identifiers by purchasing and selling entities for materials that may be FFF (Form, Fit, Function) equivalent results in semantic disconnects between the purchasing and selling entities during automated e-commerce processes. This semantic disconnect requires intervention and participation of technical experts in buying and selling entities to determine whether parts that buyers want to buy and parts that sellers want to sell are form, fit and function equivalent. This participation and manual intervention by experts to determine FFF equivalency slows down and adds to the cost of industrial commerce that involves direct and stockable MRO materials.
[0005] [0005]FIG. 1 illustrates examples of buy side applications 100 , sell side applications 102 and a plurality of procurement private trade exchange (PTX) based applications 110 . The PTX applications 110 may include a demand aggregation application 112 , a request for quotation (RFQ)/Quotation application 114 , and an auctioning/bidding application 116 .
[0006] In the private procurement trading exchange (PTX) 110 , a procuring entity 100 may deploy multiple buy-side enterprise systems 104 A- 104 C. Alternatively, the systems 104 A- 104 C may represent computer systems of multiple enterprises. The procuring entity's systems 104 A- 104 C may have more than one part number for parts that are form fit function (FFF) equivalents. Similarly, for the multiple sell-side participants 106 A- 106 C, each sell-side participant 106 may have a different part number for parts that are form, fit, and function equivalents.
[0007] Buyers 104 A- 104 C on the buy side 100 and sellers 106 A- 106 C on the sell side 102 may have multiple part numbers for form, fit and function (FFF) equivalent products. A part's form, fit and function (FFF) equivalent is defined by a set of specifications, which may be represented as a taxonomy instantiation. For example, a computer manufacturer 104 B on the buy side 100 may identify an electronic component, e.g., a dynamic random access memory (DRAM), which the manufacturer 104 B wishes to buy, with a part number “4711” in the manufacturer's enterprise computer systems. A supplier 106 C on the supply side 102 may internally call its DRAM product “WXYZ” in the supplier's computer systems. These internal part numbers (IPNs) may be linked to each company's internal software applications, such as financials, inventory, sales, etc.
[0008] When manufacturers 104 A- 104 C buy components and materials from suppliers 106 A- 106 C, it is important that the suppliers' parts (e.g., “WXYZ”) be form, fit and function (FFF) equivalents to the part (e.g., “4711”) required by a buyer 104 . While there might be thousands of DRAM products available in the global electronic marketplace, none or few products may be a FFF equivalent to what the buyer 104 needs.
[0009] A computer manufacturer 104 may wish to electronically solicit potential additional sources of supply for DRAM by using an e-procurement system to send RFQs to potential new suppliers 106 A- 106 C around the world. A problem arises when the potential sources of supply, i.e., companies 106 A- 106 C that manufacture or distribute DRAM, do not recognize “4711” since each supplier 106 has its own part numbers for DRAM products. A supplier 106 receiving an electronic request for quotation (RFQ) 114 for part number “4711” would have no way of knowing what the part number “4711” represents, unless additional information is available. Similarly, a buyer 104 receiving a solicitation to buy “WXYZ” from a supplier 106 C would have no way of knowing whether the “WXYZ” part is an FFF equivalent to “4711.”
[0010] Free form product specifications (text) that accompany a product or RFQ do not solve the problem because specifications developed by the buyer 104 may not map directly to specifications developed by a seller 106 . Free form text may also require people to read and process the text.
[0011] The product semantics disconnect (different part number problem) constrains buyers 104 A- 104 C from finding additional sources of supply in the global electronic marketplace, and constrains suppliers 106 A- 106 C from electronically promoting their products to buyers 104 A- 104 C. Especially in exchange environments 110 , heterogeneous part numbering constrains applications like demand aggregation 112 , electronic auctioning and bidding 116 and electronic RFQ/quotation exchanges 114 , because these applications may require a single part number to process.
[0012] In addition, as illustrated in FIG. 1, a large or diverse buying entity on the buy side 100 may have different part numbers in different divisions 104 A- 104 C for FFF equivalent items due to mergers, acquisitions and legacy part numbering systems. Also, specifications for the different products may have been developed at different times by different engineers and may not be consistent.
[0013] Today, the problem of determining FFF equivalency is addressed through procedures and additional human-to-human communications between buyers 104 A- 104 C and sellers 106 A- 106 C. But the procedures and additional human-to-human communications limit the speed and efficiency of the buy/sell process, and fail to take advantage of the potential vast productivity gains to be realized through e-commerce on the World Wide Web (WWW).
[0014] Supply Chain FIG. 2 illustrates an example of a supply chain 200 . The supply chain 200 includes manufacturers 202 , franchised component distributors 204 , independent component distributors 206 , original equipment manufacturers (OEMs) 208 , value added distributors (VAD) 210 , value added resellers 212 , an end customer 214 , component manufacturers 216 , component brokers 218 and contract manufacturing services (CMS) or contract electronics manufacturer (CEM) 220 . FIG. 2 also depicts the use of the Electronic Component (EC) catalog taxonomy (ECCT) and the Information Technology (IT) catalog taxonomy (ITCT) segments of a version of the RosettaNet Technical Dictionary (RNTD).
[0015] A CEM is a provider of manufacturing services to original equipment designers (OEDs). Component manufacturers may send part specifications to the OED. The OED sends documents to the CEM, including the OED's approved manufacturer parts list (AMPL) and “customer (from the CEM's perspective) bill of materials (BOM) (see FIG. 11).” The CEM's customer is the OED, and from the OED's perspective, customer BOMs are OED-created BOMs using the OED's Internal Part Numbers (IPNs). Cross reference of customers' AMPLs and BOMs provide information to the CEM as to which parts (e.g., MPNs and/or VPNs) can be purchased in order to manufacture equipment for the OED, based on the OED's BOM.
[0016] The OEMs 208 and CEMs 220 may buy components from the distributors 204 , 206 and component brokers 218 , who buy the components from the semiconductor manufacturers 202 and electronic component manufacturers 216 . In some cases, the OEM 208 may buy components directly from the electronic component manufacturers 216 . CPTI may enable OEMs 208 , OEDs and CEMs 220 to more easily buy directly from component manufacturers 216 , rather than purchasing via distributors 206 .
[0017] In some cases, distributors 206 provide the added value of helping buyers identify sources of supply or sellers identify customers for FFF specific components. Distributors 206 may create knowledge of which part numbers may be FFF equivalents.
[0018] The semantics disconnect problem may compound at each level of the global industry supply chain 200 . For example, a manufacturer's part number (MPN) of a component manufacturer 202 (e.g., semiconductor manufacturer) is often given different vendor part numbers (VPNs) by distributors 204 , 206 and component brokers 218 . A manufacturer's part number (MPN) is a product ID given by a manufacturer to a component made by the manufacturer. The MPN is assigned by the component's original manufacturer, e.g., manufacturer 202 . A variation of this is where an MPN's manufacturer is not the original manufacturer, but manufacturers a FFF equivalent to the original MPN, and assigns an MPN that is a recognizable variant of the original manufacturer's MPN.
[0019] A vendors' part number (VPN) is a product ID of a component assigned by a vendor. Technically, the vendor could be the manufacturer, and therefore the VPN could be the MPN. Typically, the term “vendor” applies to distributors, who may assign their own part numbers because the distributor/vendor may resell components from multiple manufacturers that are FFF equivalent and may sell these under one VPN identifier.
[0020] From a buying organization's perspective, an internal part number (IPN) may be a product identifier for a procured, stockable (inventoried) material or component. For example, in the SAP R/3 Enterprise Resource Planning (ERP) system, an IPN may represent a “material master” object, which is a master record or representation of a product. The material master may have a raw or purchased material type. The material master identifier may be the same as a part ID or a product identifier. If an item is stockable, like direct materials or stockable MRO, then the item may be identified in the system as a material master before any transactions for the material item can be performed by the system. The system needs information from the material master to trigger application logic. A material master may be separated into different “views,” such as a basic data view (e.g., with description and unit of measure), a sales view (e.g., with sales prices and sales unit of measure), a planning view (e.g., with reorder point and MRP parameters), a costing view (cost), etc.
[0021] A “material master” in SAP's R/3 system may be known by another term in other enterprise or e-selling or e-procurement systems. For example, in SAP's e-procurement system Enterprise Buyer Professional (EBP), part numbers created in the system are called “product masters.” In stockable maintenance, repair and operations (MRO) environments, the IPN is the identifier (ID) under which procured equipment spare part components are stocked. In direct material environments, the IPN is used to manage stocked materials and is also the ID for procured components in a bill of materials (BOM).
[0022] Original equipment manufacturers (OEMs) 208 are original designers and manufacturers of equipment, which can be assembled from procured mechanical, electrical and passive components. Original equipment manufacturers (OEMs) 208 have internal part numbers (IPNs) for components in their bills of materials (BOMs). Each of these IPNs may be linked to an approved manufacturers list (AML) (known in SAP R/3 as an Approved Manufacturers Part List (AMPL), and in some other systems, an AVL (Approved Vendors List)) (see AMPL 1124 in FIG. 11). The AMPL 1124 contains multiple FFF equivalent MPNs, VPNs and/or EPNs 1126 A- 1126 C that have been pre-approved for purchase, typically by a procurement engineer, when a net requirement exists for the IPN to which the AMPL has been linked. By definition, each MPN, VPN, or EPN in the AMPL is interchangeable or an FFF equivalent to the IPN, i.e., share a set of common specifications or attributes. All approved part numbers in the AMPL should function properly when used in the product manufactured under a BOM, or when used as a replacement part in the product.
[0023] A contract manufacturer (CM) 220 in FIG. 2 may need to maintain BOMs of IPNs with associated AMPLs for multiple OEM customers in the CM's system. The OEM customers can easily have different IPNs for items that are FFF equivalent. These IPNs from different OEMs 208 will have different AMPLs, which may often have a high degree, but not total, overlap. For example, an AMPL for one OEM's IPN may contain some MPNs or VPNs which are also included in AMPLs for other OEMs IPNs.
[0024] In manufacturing industries, net materials requirements planning (MRP) is performed on the IPNs in BOMs. A purchase order (PO) is generated for the IPN and the PO also contains one of the FFF-equivalent approved parts in the AMPL 1124 . This allows the selling company to know which part number (e.g., the approved part number) is selected from the AMPL. A selected MPN 1126 B is received into the buyer's inventory as a specific part number IPN3 1112 , i.e., the identity of the MPN 1126 B may be lost with the receipt-to-stock transaction. A purchasing company will often buy different approved parts from the AMPL 1124 with different POs. Thus, multiple, different approved parts 1126 A- 1126 C may be carried physically in inventory under the IPN3. All of the approved parts 1126 A- 1126 C in the AMPL 1124 should be FFF equivalents to the IPN3 1112 . Otherwise, the approved parts 1126 A- 1126 C may not function within the product (e.g., a computer) manufactured from components in the product's BOM structure 1100 .
[0025] The term “approved” in AMPL indicates that each part listed in the AMPL has been tested and “approved” as being a FFF equivalent to the specifications or attributes of the IPN. Two MPNs with similar specifications are not necessarily FFF equivalent, since the specifications may not be precise enough to ensure that the parts are FFF equivalent. Thus, there is a need for an “approved” manufacturer's parts list (AMPL). Parts are usually designated as approved after testing to make sure they function properly in the equipment within which they are used.
[0026] GTIN
[0027] One proposed standard part numbering solution is the Global Trade Item Number (GTIN). A GTIN represents a specific manufactured product. The GTIN is a 14-character, non-intelligent, numeric identifier that includes a packaging code, a company code, a sequential identifier and a “check digit.” It is identical to the EAN/UCC-14. There is a one-to-one correspondence between a GTIN and a specific manufactured product. A GTIN may be assigned sequentially by a manufacturer or a consortium. GTINs were designed for buyers and sellers to use the same part number throughout the supply chain, rather than each using their own, self-assigned part numbers. Thus, GTINs would streamline product information flow.
[0028] GTINs are limited because there is no semantic relationship between a part's GTIN and the part's FFF. If a buyer submitted an RFQ with a particular GTIN, the seller would not be able to easily or quickly derive the part's FFF to determine whether the seller had a product to offer. So while buyers can use seller's GTINs after they become known to a seller, a buyer RFQing a new supplier does not yet know the new seller's GTIN for the part that the buyer wants, or indeed whether the new seller has such a product. Nor can the new seller determine from the buyer's internal part number what the buyer wants to buy.
[0029] RosettaNet (see www.rosettanet.org) is a consortium of 400+ companies in the high tech and electronics industry. RosettaNet states that where a one-to-many relationship exists between a buyer's IPN and possible FFF equivalent part numbers from suppliers, the Approved Manufacturers List (AML) or Approved Manufacturers Part List (AMPL) may be used. The buyer can continue to use the same IPN, rather than using a supplier's GTIN as the buyers IPN. This is desirable for manufacturers because if the buying manufacturing company created IPNs using the sellers' GTINs, the buying manufacturing company may have multiple FFF equivalent IPNs. This may result in the buyer's MRP system generating a net requirements for a given IPN even though there might be available inventory of another FFF equivalent IPN. Thus, manufacturers may desire to use the AMPL rather than GTINs.
[0030] RosettaNet allows for use of GTINs for distributors and use of AMPLs for manufacturers. RosettaNet has defined a Partner Interface Process (PIP) for the AML, aka AMPL (Approved Manufacturers Parts List). The IPN with AML is more conventionally used in enterprise systems by electronics manufacturing companies than GTINs.
SUMMARY
[0031] The present application relates to the process of providing a Collaborative Product Taxonomy Instantiation (CPTI) as part of a collaborative taxonomy, which may be a component of a Cross Application Product Taxonomy Management (xPTM) system.
[0032] A CPTI of the invention eliminates semantic disconnects in direct materials and stockable MRO supply chains, which are caused by heterogeneous or disparate product identifiers, by providing a unifying identifier understood by the various parties to a communication. For ease of reference the unifying identifier will be referred to as an Exchange Part Number (EPN) that may be an alphanumeric value. The CPTI process recognizes that trading partners (e.g., business enterprises) within commerce communities have different, mutually incomprehensible, part numbers for products that may be equivalent e.g., have the same form, fit and function (FFF). For ease of description FFF will be used to define equivalents for purposes of grouping objects under one EPN. CPTI enables trading partners and trading communities within global industry supply chains to more readily identify sources of supply (buy-side perspective) and potential customers (sell-side perspective) using e-commerce technology.
[0033] Furthermore, the present invention recognizes that developing the instantiations in a taxonomy requires collaborative discussions or negotiations between parties. Typically the discussions or negotiations take place electronically, e.g. over the internet, to allow more than two parties to easily access and propose changes to an instantiation, e.g., through the use of a collaborative folder or other exchange technology. As such, the present invention proposes using an existing base taxonomy as the starting point for collaboration. Each instantiation, defines an object (e.g., DRAMs) having certain attributes or parameters (e.g., voltage tolerances, temperature tolerances, footprint, speed, capacity), wherein at least some of the attributes have values associated with them (e.g., 5V, 80 degrees Celsius, etc.) The collaboration may relate to different aspects of the instantiation; e.g. to sub-grouping objects, adding or deleting attributes or adding or deleting value ranges.
[0034] xPTM involves the linking of the collaborative taxonomy to other applications, such as back end systems, to be integrated into the procurement, planning or other aspects of an enterprise logic system. As such xPTM may be used by design engineers (e.g., with PLM applications), and planners (e.g., with Supply Chain Management (SCM) applications) and by maintenance (Plant Maintenance (PM) applications). CPTI may be used with e-Commerce systems like e-procurement, e-Sales, Private Exchanges (PEXs or PTXs) and electronic bidding and auctioning applications.
[0035] Thus CPTI refines the concept of using standard taxonomies (e.g., the RosettaNet Technical Dictionary (RNTD, eClass or UNSPSC codes) (RosettaNet, Partner Interface Process, PIP, are trademarks of RosettaNet, a non-profit organization) to communicate FFF by adding at least two acts: (a) at least one buyer and seller collaborate to refine, customize and instantiate at least once a baseline standard taxonomy, i.e., create a collaborative product taxonomy instantiation, and (b) assigning an exchange part number (EPN) to represent the resulting collaborative taxonomy instantiation. The collaboration participants associate material master data with the resulting EPN in their respective e-commerce and e-selling systems and back office enterprise systems. EPNs resulting from the CPTI collaboration process are machine sensible after entry as material masters in the participants' systems. Machine sensible part numbers enable the e-commerce dialogue between the e-selling and e-procurement systems to be fully automated. There is no need for intervention of experts to interpret and manually enter the data in the recipients' systems, which is usually necessary when taxonomy instantiations, rather than recognizable part numbers, are sent from system to system.
[0036] Generally speaking, the World Wide Web has some limitations due to the semantic disconnects between communicating parties. Differences in terminology and other semantic differences provide a significant hurdle to free communication between parties. The term Semantic Web has been used to describe a Web where the semantic differences have been addressed. This state of Utopia has, however, not been realized in the past. The CPTI process discussed in the embodiment below may, on the other hand, be considered as a specific industrial application of Semantic Web ontology and taxonomy concepts. It will therefore be appreciated that, while the particular embodiment relates to semantic differences between buyers and sellers in naming their products, the invention is equally applicable to addressing other semantic disconnects by providing a collaborative environment and by mapping the communicating parties' terminologies to common key terms. For purposes of conciseness, a particular application of the invention will be discussed in detail below. The common key terms that serve as the link between the communication parties' terminologies will be referred to Exchange Part Numbers (EPNs). EPNs refer to a set of numbers, letters, a set of alphanumeric characters, or, in the case of Chinese, Japanese, or other non-alphabet based characters, a set of one or more characters. Since the common key words (in this case referred to as EPN) need not necessarily be viewable by a user, the EPNs could even be undefined characters (binary strings that are commonly used simply for the purpose of translating from one set of serial numbers to another). Typically, however, an EPN that is viewable and understandable by human users is preferable since it can be displayed to the communicating parties as confirmation that they are dealing with a product with the same attributes. In the embodiment discussed below, the EPN may enable automated e-procurement and e-selling of direct material components and stockable MRO materials via e-commerce documents in scenarios where buyers and sellers have different BTF part numbers for FFF equivalent items.
[0037] Buyers and sellers may be unable to understand each other's internal part numbers (IPNs), vendor part numbers (VPNs), manufacturer's part numbers (MPNs) and customer part numbers (CPNs).
[0038] Resolution of heterogeneous system product ID disconnects may enable electronic auctioning applications.
[0039] In an on-line collaboration to negotiate a CPTI the method may comprise selecting from a taxonomy a first set of attributes and values for a desired component; posting the first set of attributes and values to a collaborative environment; accessing a second set of attributes and values via the collaborative environment, wherein at least some of the attributes or values or both attributes and values in the second set are different from the first set; forming a taxonomy instantiation comprising at least some of the attributes and values from the first and second sets of attributes and values; and assigning a set of characters to the taxonomy instantiation.
[0040] Another aspect relates to a method comprising: forming a collaborative product taxonomy instantiation, the taxonomy instantiation comprising a set of characteristics or attributes of a desired product; assigning a set of characters to the collaborative product taxonomy instantiation; and using the set of characters in an electronic trading exchange application between at least one buyer and at least one seller.
[0041] Another aspect relates to an electronic commerce exchange configured to communicate with at least one product procurement software application and at least one product sales software application. The procurement software application has a first internal product identifier. The sales software application has a second internal product identifier. The invention associates a unifying identifier or key to the first and second internal product identifiers
[0042] Another aspect relates to an electronic catalog comprising a plurality of collaborative taxonomy instantiations, each collaborative taxonomy instantiation comprising a plurality of characteristics and values, each collaborative taxonomy instantiation being linked to an exchange part number.
[0043] Another aspect relates to an electronic commerce document configured to be sent over the Internet between a component buyer and a component seller. The electronic commerce document includes an exchange part number. The exchange part number is associated with a collaborative product taxonomy instantiation.
[0044] Another aspect relates to a method comprising: accessing a catalog of collaborative taxonomy instantiations; and using an exchange product number to find its collaborative taxonomy instantiation with pre-determined characteristics.
[0045] CPTI may provide many advantages or benefits. For example, purchasing companies may be able to establish additional sources of supply, which may enable the purchasing companies to procure materials with shorter lead times and for less cost as a result of having a broader range of alternative suppliers. The purchasing company may manufacture products from procured components. The shorter lead times and/or lower costs resulting from CPTI may enable the purchasing company to in turn sell their manufactured products for lower prices or to deliver assembled products in less time.
[0046] Selling companies may be able to more easily identify additional customers, which may enable them to increase sales volume.
[0047] The details of processes and systems are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0048] [0048]FIG. 1 illustrates examples of a buy side, a sell side and procurement private trade exchange (PTX) based applications.
[0049] [0049]FIG. 2 illustrates a high tech industries supply chain and levels of the chain where the RosettaNet RNTD might be used as a basis for a catalog taxonomy.
[0050] [0050]FIG. 3A illustrates a collaborative product taxonomy instantiation (CPTI) process.
[0051] [0051]FIG. 3B illustrates an example of an SAP PLM System collaborative folder as an environment for collaboration on a baseline taxonomy as described in FIG. 3A.
[0052] [0052]FIG. 4 illustrates an example of multiple buy-side systems, exchange applications and sell-side systems where an exchange part number (EPN) is mapped to multiple FFF equivalent BTF part numbers.
[0053] [0053]FIG. 5 illustrates an example of integrating CPTI into a broader set of functions as part of a cross application product taxonomy management (xPTM) system.
[0054] [0054]FIG. 6 illustrates the Cross Application Product Taxonomy Management (xPTM) process of FIG. 5 with a view of user roles.
[0055] [0055]FIG. 7 illustrates examples of RosettaNet Technical Dictionary (RNTD) version 1.4 classes, property sets, properties and property value expressions.
[0056] [0056]FIG. 8 illustrates a market exchange scenario with buyers, a marketplace and sellers using exchange part numbers (EPNs) as generated by a CPTI process.
[0057] [0057]FIG. 9 illustrates mapping of buyer part numbers and seller part numbers to EPNs resulting from a CPTI process in order to bridge the semantics disconnects that would otherwise result from buyers and sellers having different part numbers for parts which are FFF equivalents.
[0058] [0058]FIG. 10 illustrates CPTI catalog related terms, including a taxonomy, a taxonomy instantiation, a search engine and a part number associated with the taxonomy instantiation.
[0059] [0059]FIG. 11 illustrates a bill of materials (BOM) for a parent item (e.g., a computer) and an approved manufacturer's parts list (AMPL) for a component of the parent item.
[0060] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0061] An industry-specific (high tech) example of Collaborative Product Taxonomy Instantiation (CPTI) is described herein. The principles of collaborative product taxonomy instantiation, however, are equally applicable to any manufacturing industry, such as automotive, aerospace, consumer goods, apparel, etc.
[0062] Taxonomies
[0063] A “taxonomy” is a set of classes, characteristics and values used to describe and catalog a plurality of objects (also called items, components, parts, products or materials). As used herein, “characteristics” in a taxonomy may also be called properties, attributes or specifications. The objects may be grouped into a “class” or “category.” A taxonomy may also be called a “classification schema” or a “catalog search schema.”A “product taxonomy” is a taxonomy used to categorize a set of products.
[0064] Several industry consortiums are developing taxonomies. For example, RosettaNet (see www.rosettanet.org) has developed an openly available, standard taxonomy (or classification schema) in response to the product numbering problem. RosettaNet's standard taxonomy is called the RosettaNet Technical Dictionary (RNTD). Computer and electronics companies may use the RNTD to describe and catalog electronic components, semiconductors, Information Technology (IT) equipment and other products.
[0065] [0065]FIG. 7 illustrates examples of RNTD classes 700 , property sets 702 , properties 704 and property value expressions 706 . RNTD version 1.4 contains approximately 741 classes, 2,647 properties and 610 property sets. An example class is Memory—Dynamic RAM (DRAM), which includes seven property sets (e.g., “Semiconductor Package,” “Semiconductor Common Set”) and 105 properties, (e.g., “High Level Output Voltage”). RNTD property value expressions include a property domain (e.g., “integer” or “string”) and property units (e.g., “volt” or “kilogram”), and others.
[0066] Standard taxonomies may serve two complementary purposes:
[0067] Provide a common meta-language in e-commerce for buyers and sellers to describe products and services in mutually comprehensible terminology; and
[0068] Use as search schemas in electronic catalogs (procurement or sales catalogs), which enable users to find product part numbers through selection or specification of product attributes.
[0069] As used herein, an “electronic catalog” (“e-catalog”) is a computer-based catalog and does not refer to traditional paper catalogs.
[0070] An “exchange catalog” is a catalog accessible by computers of all enterprises within a trading community.
[0071] Electronic catalogs may already exist, typically at a seller's web site or behind the firewall as an internal catalog on the buy side. But a seller's catalog taxonomy and a buyer's catalog taxonomy currently may not be compatible (may not map category/attribute/value to category/attribute/value). The idea of using standard catalog schemas/taxonomies (to make it easier for buyers and sellers to precisely understand whether what is being sold is/is not the same as what is being bought) has not been widely implemented.
[0072] Taxonomies in a procurement private trading exchange (PTX) may provide a basis for:
[0073] Classification of internal part numbers (IPNs) and identification of part numbers that are FFF equivalent to other part numbers (resulting, for example, from mergers), which enables demand aggregation and excess inventory reduction;
[0074] Representation of common attributes of the IPN and the MPNs and/or VPNs in an AMPL.
[0075] Taxonomies in a sales PTX may provide a basis for creating a sales PTX catalog search schema.
[0076] Multiple Part Numbers on the Buy Side and Multiple Part Numbers on the Sell Side
[0077] There are at least two e-commerce examples with multiple part numbers on the buy side 100 (FIG. 1): (a) a multi-division legal purchasing entity has multiple form, fit, function equivalent IPNs, which may be true of an enterprise operating a private procurement exchange 110 , and (b) in the case of a public exchange, where multiple buy-side exchange participants collaborate in order to be able to aggregate demand.
[0078] A company operating a private procurement exchange (PTX) may have multiple FFF equivalent IPNs in their BOMs because:
[0079] The company's technology infrastructure may not be able to determine whether a required FFF equivalent IPN already exists before creation of a new IPN. For example, existing IPNs may not have all been categorized in a schema/taxonomy to enable a search to determine whether a required IPN exists.
[0080] Procedures to search and determine whether FFF equivalent IPNs exist before creating a new IPN may not be in place or may not be followed.
[0081] The company operating the PTX may have acquired other companies and still be using the acquired companies' legacy ERP systems.
[0082] The company operating the PTX might be a Contract Electronics Manufacturer (CEM) with multiple customers (OEDs that purchase contract manufacturing services from the CEM), where the customers (OEDs) have products containing FFF equivalent components with different part numbers. For example, two different computer OEDs may always have different IPNs for FFF equivalent parts since they may use different techniques or systems to generate part numbers for their IPNs.
[0083] There may be a key difference between the IPN/MPN relationship in B2B scenarios and in exchange-based scenarios. In B2B scenarios, there may be a one-to-many relationship between the IPN and various MPNs and VPNs (assuming no acquisitions, adequate procedures and technology). In public exchange-based scenarios, where there are multiple buy-side exchange participants, there is always a many-to-many relationship between buy side IPNs and sell side MPNs and VPNs.
[0084] Demand Aggregation
[0085] The multiple IPN scenario makes it difficult to aggregate demand to arrive at quantity for auctioning/bidding and RFQ/Quotation scenarios. For example, in FIG. 1, individual MRP planning runs to calculate net requirements in the back-end systems would result in separate planned requirements for the FFF-equivalent IPNs 1234, 4711 and 7890, such as:
[0086] 1234=100
[0087] 4711=100
[0088] 7890=100
[0089] Seller Understanding of IPN
[0090] A related problem occurs in RFQ/Quotation scenarios: either in single (or multiple buying companies) to single (or multiple selling companies) B2B scenarios. A recipient 106 of the RFP/RFQ will by definition not understand the procurement entity's IPN. So even if demand for the multiple FFF equivalent IPNs were aggregated under a single part number (for example 300 units of IPN 4711), the seller 106 would not be able to respond the RFQ with a Quotation. The seller 106 will not understand the part number “4711.”
[0091] Taxonomy Instantiations
[0092] The following excerpt from a RosettaNet document entitled “(PIP) Partner Interface Process 2A9/10 Query/Respond Technical Product Information,” illustrates a taxonomy used as meta-language. The excerpt is an example of an e-commerce dialogue between a purchasing company (e.g., a buyer 104 in FIG. 1) and a group of distributors or sellers 106 A- 106 C. The buyer seeks to identify possible sources of supply (i.e., distributors or sellers 106 A- 106 C) for a DRAM computer component (represented in the RNTD as class XJA644 (Memory—Dynamic RAM)).
[0093] Query sent by Purchasing Company/OEM:
[0094] RosettaNet Class=“XJA644”
[0095] Voltage=“5”
[0096] Rated Maximum Power=“GT 4 AND LT 6”
[0097] Pin Count=“24”
[0098] Response sent by Distributor 1:
[0099] RosettaNet Class=“XJA644”
[0100] Voltage=“5”
[0101] Rated Maximum Power=“GT 4 AND LT 6”
[0102] Operating Temperature=“50”
[0103] Is Generic=“1”
[0104] Pin Count=“24”
[0105] Response sent by Distributor 2:
[0106] RosettaNet Class=“XJA644”
[0107] Technology=“CMOS”
[0108] Voltage [min]=“1.1”
[0109] Voltage [max]=“5.5”
[0110] Rated Maximum Power=“GT 4 AND LT 6”
[0111] Operating Temperature [min]“45”
[0112] Is Generic “1”
[0113] Pin Count=“20”
[0114] “E-Commerce documents” may be in XML format and are transmitted via the Internet to a recipient. An “e-commerce dialogue” is an exchange of documents, for example as specified in a RosettaNet Partner Interface Process (PIP). For example, Buying company A sends an RFQ (Request for Quotation) document with specifications for a product to Selling Company Z. Selling Company Z may respond with a Quotation document for a specific product. Buying company A may respond with a Purchase Order document for the specific product. Selling company Z may respond with an Order Confirmation document for the specified product. Selling company Z may send an Advanced Shipment Notification (ASN) document for the specified product.
[0115] The dialogue above illustrates the use of RNTD taxonomy “instantiations” to define what is needed by a buyer and what is available from sellers. A “taxonomy instantiation” includes a set of properties (or attributes or characteristics) selected from a class (or category) in a base taxonomy, e.g., RNTD, and values selected or specified for the attributes. For example, the attributes/properties above were selected from seven property sets and 105 properties associated with the DRAM class in RNTD. This use of the RNTD as a commonly understood meta-language enables the members of the trading community to engage in a commerce dialogue. But this dialogue is not yet an automated dialogue.
[0116] Human involvement may be necessary in an e-commerce document exchange when the receiving system cannot automatically process the incoming document. This could be for several reasons. For example, the document may contain a part number not recognized by the recipient's system (because a material master had not been previously created). Alternatively, the document could be in the wrong format, i.e., the incoming document contained a taxonomy instantiation that is not machine sensible by the recipient's system because of one of several reasons. Most likely, the recipients system may not have transactions like “Import taxonomy instantiation” and “Search via classification (a.k.a. taxonomy).” Another reason is the recipient may not have categorized parts into the taxonomy. Another reason is the sender and the recipient might have used different taxonomies.
[0117] If the buyer organization 104 (FIG. 1) had used its internal part number (IPN) “4711” to represent DRAM without additional information or dialogue, the sellers 106 A- 106 C would not have been able to respond. In most cases, the part number alone does not convey the required information, and would therefore require additional dialogue.
[0118] A buying organization 104 may not know the selling organization's MPN for the buyer's FFF equivalent IPN. If both commerce partners use the same standard schema/taxonomy, the buyer 104 may provide the seller 106 with a set of attribute values as a means of specifying what the buyer 104 would like to purchase.
[0119] The example above describes a dialogue where a single buying company corresponds with multiple distributors to determine whether the distributors have an available electronic component that is form, fit, function (FFF) equivalent to what is required by the buyer. The dialogue includes only seven of the 105 properties included in the class for DRAM class XJA644. Rarely would a buyer need to specify values for all 105 of the properties for DRAM to describe a DRAM to a degree of specificity required by the buyer to determine that the manufacturers offering might be FFF equivalent.
[0120] The PIP dialogue example above does not actually describe a collaborative taxonomy instantiation process (described below) but rather an exchange of information initiated by a buyer to identify sources of supply, probably to populate an AMPL.
[0121] A key difference between the PIP dialogue above and the collaborative taxonomy instantiation process described below is that the PIP dialogue does not result in a collaborative taxonomy instantiation. The collaborative taxonomy instantiation process (below) precedes the actual buy/sell process. The collaborative taxonomy instantiation process (below) enables the buy-sell process to function in a much more automated way since an exchange part number (EPN) is linked to a collaborative attribute/value set, based on a standard taxonomy, which represents an agreed upon degree of specificity to represent FFF equivalency.
[0122] In one configuration, the collaboration process may also occur via a web-accessible PLM Collaborative Folder (FIGS. 3B and 5), where a segment of the RNTD in the spreadsheet format (also available at rosettanet.org) is accessed and collaboratively modified by trading partners. The trading partners highlight the most relevant properties of a product taxonomy, and optionally specify additional properties, then specify values for the properties. In another configuration, the trading partners may access a web-accessible catalog maintenance environment, where the baseline taxonomy has been imported and the created as a catalog search schema.
[0123] Shortcomings of Standard Taxonomies
[0124] While standard taxonomies, such as the RNTD taxonomy-based approach specified by RosettaNet PIP2A9/10, may provide a basis for addressing the different part numbering problems in a supply chain, they may not solve the problem.
[0125] Reasons for the problem include the following:
[0126] Taxonomy instantiations are not generally “machine sensible” by computers.
[0127] So if the buyer's e-procurement system is able to transmit a taxonomy instantiation (at least as free form text contained in a field within a Request for Quotation (RFQ) e-commerce document), the sellers' e-selling system would not be able to automatically process the RFQ e-commerce document for a product represented using this technique. Nor could the buyer's e-procurement system automatically process quotation documents from the seller's system containing taxonomy instantiations like the examples shown above.
[0128] One exception in a “mySAP” Sales and Distribution (SD) module of SAP's R/3 ERP system, which may be able to import and process a sales configuration instantiation received from an SAP Customer Relationship Management (CRM)/Internet Pricing Configurator (IPC)'s Sales Configuration Engine (SCE). SAP's R/3 Sales and Distribution module includes sales order entry and management, including pricing, tax calculation, availability checking, and triggering of accounts receivable. SAP R/3's SD component can receive a taxonomy instantiation from another SAP component, the Sales Configuration Engine (SCE).
[0129] But this system is not operative in the e-commerce environment of CPTI, because the SAP components SD and SCE are homogeneous systems, not heterogeneous. Both SD and SCE components can process the same so-called product configuration Knowledge Base (KB), which comes from the same maintenance environment (e.g., PLM). This is not true in a trading community environment where the participants likely have heterogeneous software and/or computer systems.
[0130] Even if a trading partner's system could automatically send (most can, at least as text) taxonomy instantiations, and even if a recipients' system could automatically process taxonomy instantiations (most systems cannot initiate an electronic catalog search to find a product corresponding to the FFF expressed in the taxonomy instantiation), it would still be necessary for the commerce partners to have cataloged their products using the same taxonomy as the transmitted taxonomy instantiation (e.g., an instantiation based on the RNTD). Realistically, many enterprises have not done this massive cataloging project, or at least have not cataloged a critical mass of their products for the same release version of the same taxonomy at the same time. This is because:
[0131] Taxonomies evolve. For example, the RNTD is at version 2.0 and still evolving. Even when the buyers and sellers use a standard taxonomy, like RNTD, there is the issue of multiple versions. The current version 2.0 differs substantially from its predecessors, e.g., version 1.4.
[0132] Taxonomies can be very deep and very broad. For example, the RNTD version 1.4 has approximately 741 classes, 2,647 properties, 610 property sets and an unlimited number of property values. It may be prohibitively expensive for a manufacturer with a large product range to catalog all of its products at all levels of detail of the taxonomy.
[0133] The RosettaNet PIP 2A9/10 approach of exchanging taxonomy instantiations, rather than part numbers, may not be useable by all e-commerce and enterprise systems. Even if the receiving system is capable of automatically receiving and processing a taxonomy instantiation (i.e., populate attribute value sets in transactions like “Import taxonomy instantiation” and “Search via Classification”), it would still be necessary for part numbers in the receiving system to have been previously categorized into the taxonomy, so that the “Search via Classification” transaction would yield a result.
[0134] To use a taxonomy and assign a part number, for example in SAP's R/3 Enterprise system, there is a view of a material master (used to represent a product, or part number, or part indentifier in the BTF enterprise system) called the Classification View. First, the taxonomy should be replicated in the ERP system. In R/3, this may be done via a series of transactions:
[0135] Create characteristics (e.g., “Resistance Value”) and values (e.g., “2200 Ohms, 1100 Ohms”)
[0136] Create class (e.g., DRAM)
[0137] Link the characteristic Resistance Value to the class DRAM (the characteristic values are linked automatically since the values are previously linked to the characteristic)
[0138] Create the classification view of a material master.
[0139] In a transaction called “Maintain Material Classification,” a view in the material master, a user classifies a material=DRAM=“4711” into the class/attribute/value set for the “DRAM” class. The user specifies the name of the class, e.g., “DRAM.” Upon entry of the class name into the transaction, the system displays all of the characteristics and values for the class. For example, the characteristic “Resistance Value” and the values “2200 Ohms, 1100 Ohms.” If DRAM “4711” uses 2200 Ohms, then the user selects the characteristic value “2200 Ohms” (as well as all other relevant characteristics and values for the material 4711). The user then “saves” this class instantiation, which is linked to the material.
[0140] The saved class instantiation enables the user to find the material/part number for DRAM 4711. The user enters the class “DRAM” in the transaction “Search via Classification,” or selects from a drop-down list. The system automatically displays all characteristics and values linked to the class (in this case, the characteristic Resistance Value and the values 2200 Ohms, 1100 Ohms. If the user wants to find the part number for a DRAM component requiring 2200 Ohms, the user clicks on the characteristic value “2200 Ohms,” which prompts the system to list the part number for the 2200 Ohm DRAM component, which in this example is 4711.
[0141] The example above only discusses linking characteristics and values to the class “DRAM” which is linked to the material component “4711.” The example describes the set-up required to find a material (e.g., DRAM component 4711) via its characteristics, using a catalog search engine or an internal classification system, like the one that exists in SAP's R/3.
[0142] The example above is a description of a simple catalog taxonomy. In direct materials procurement, it may be necessary for a procured item to be FFF equivalent to what is needed by the buyer, and the taxonomy may be much more complex. For example, the RNTD version 1.4 DRAM class has 105 properties. Each property can have a very wide range of allowable values. Thus, a buying entity's process of categorizing all of its parts into a taxonomy, like the RNTD, may be a massive project with massive costs, especially when considering parts databases of tens or hundreds of thousands of parts.
[0143] While some companies may recognize the benefit of using taxonomies, they may also recognize that the benefit can only be realized if the buying companies' sell-side trading partners have also categorized all of their parts into the same schema. Generally, industries may recognize the value of using taxonomies, but have not done it yet because it is a very expensive process. The ROI potential of this process may not be significant until a critical mass of companies within an industry have categorized their parts. As of today, only a very small percent of companies may have made the investment.
[0144] Even in high tech, which is generally recognized as being much more advanced in the standards arena than other industries, companies may wait before adopting taxonomy standards because the standards are still evolving. For example, RNTD has already been revised several times. If a buying company categorized all parts based on RNTD 1.4, and a selling company categorized based on RNTD 2.0, a schema/taxonomy instantiated and generated by the buying company may not be automatically processed by the selling company. Even if the selling company's system had the necessary “Search via classification” transaction or used an electronic catalog, the selling company cannot automatically process the taxonomy instantiation because each of the two revisions could have characteristics and/or values that the other did not.
[0145] The supply-chain disconnect caused by different part number semantics may require phone calls and e-mails in order for buyers and sellers to determine the Form, Fit, Function specifications. These actions fail to take advantage of the potential ROI of e-selling and e-procurement systems in all environments, including public and private procurement and sales exchanges, as well as electronic auctioning and bidding systems.
[0146] Even if buyers and sellers agree to use a standard taxonomy, and even when their respective e-selling and e-procurement systems can send and receive taxonomy instantiations (class, property, value combinations), typically these systems require a part number to trigger the applications. This means that a recipient of an RFQ based on a taxonomy instantiation, for example, would still be required to “manually” examine the taxonomy instantiation, and then search with tools to see if a part number exists in the seller's parts database with the FFF described in the taxonomy instantiation sent by the buyer. This is because the seller's system likely would not be able to automatically trigger a taxonomy based search for a part number corresponding to the form, fit, function described in the taxonomy instantiation.
[0147] This manual search step breaks the efficiency of the automated e-commerce dialogue, even in the best case, where the seller uses the same taxonomy as the buyer—as the RosettaNet industry consortium envisions with the RNTD.
[0148] Buy- and sell-side e-commerce systems can automatically process part numbers, if the part numbers have been created as master data within the e-commerce systems. However, where buying or selling entities receive an e-commerce document containing a part number where the part number has not previously been defined as master data, the document recipient's system will not be able to automatically process the document.
[0149] The Internet offers the prospect of either buyers or sellers being able to more easily contact a larger number of prospective customers or vendors. But the problem of buyers and sellers not being able to automatically process e-commerce documents where the trading partners' part numbers are not known compounds with each additional potential trading partner.
[0150] Therefore buyers and sellers require an efficient way to determine FFF equivalency without extraneous dialogue between buyers and sellers.
[0151] There are two related techniques to represent FFF equivalency: representation as a taxonomy/schema instantiation and representation as a part number derived from or linked to a taxonomy/schema instantiation.
[0152] The first technique involves representing the commerce object (e.g., an electronic component) as a taxonomy/schema instantiation. For example, the following may be a taxonomy instantiation in an XML document format:
[0153] <Resistance Value>220 Ohms</Resistance Value
[0154] <CircuitDesignator>IndependentCircuit</Circuit Designator>
[0155] <TR Tolerance>+/−5% and TCR +/−100 PPM/C</TR Tolerance>
[0156] <Packaging Type>Tube</Packaging Type>
[0157] <Number of Terminals>16</Number of Terminals>
[0158] <Package Style>QSOP</Package Style>
[0159] <Product Class>Thin Film on Silicon</Product Class>
[0160] A problem with this technique is that generally very few e-commerce systems can automatically process documents containing schema instantiations, although many e-commerce systems can process documents containing part numbers, if the part number has previously been defined as master data.
[0161] Information needed by e-selling and e-procurement applications is typically linked to a part number. The R/3 part number length may be 18 characters in length. Other systems may support longer part numbers. Only very few (if any) e-commerce systems would be able to support product representations as long as a schema instantiation for a technical product.
[0162] A heterogeneous systems environment is a trading exchange environment where the buy-side and sell-side participants use a variety of packaged software and/or in-house developed systems. In such environments, there are no scenarios where the participant's e-commerce and back office systems would generally all be able to process schema/taxonomy instantiations in the way that they are able to process part numbers today. On the other hand, many business application systems use the technique of linking part numbers to additional information that is meaningful to a system, e.g., e-selling, e-procurement, supply chain management, Enterprise Resource Planning (ERP) systems.
[0163] This leads to the possibility of using a technique where FFF equivalency can be modeled as a part number: either as a part number derived from a schema instantiation, or as a sequentially-generated, internally assigned number linked to a schema instantiation. For example, the sequentially generated, internally assigned number may be generated by R/3 PLM and then linked to a schema instantiation using Stockable Type or Product Type creation capability with PLM under R/3's Variant Configuration capability.
[0164] Collaborative Product Taxonomy Instantiation (CPTI)
[0165] CPTI is a collaborative solution that resolves disconnects related to different product part numbers and removes constraints to e-commerce within trading communities. CPTI incorporates standard taxonomy concepts and addresses the above-mentioned problems. To address the above-mentioned problems, the CPTI process may include enhancing and customizing a baseline standard taxonomy; creating an instantiation (specifying attributes and attribute values); and assigning an exchange part number (EPN) to represent the instantiation in e-commerce documents.
[0166] [0166]FIG. 3A illustrates a collaborative product taxonomy instantiation (CPTI) process.
[0167] I. In a block 330 of FIG. 3A, the CPTI process includes a pre-commerce process of one or more buyer(s) and seller(s) agreeing on a baseline taxonomy and creating a collaborative taxonomy instantiation by adding, changing and/or deleting form, fit and function characteristics and values. Thus, the buyer(s) and seller (s) agree upon a level of form, fit and function) equivalency.
[0168] A “collaborative product taxonomy instantiation” is a collaborative creation of a taxonomy instantiation based on an agreed upon taxonomy where the trading community members agree that the instantiation represents a level of Form, Fit, Functional equivalence.
[0169] II. In a block 332 , the entity operating the exchange (e.g., buying enterprise) designates an exchange part number (EPN) to represent the collaborative taxonomy (C-Tax) instantiation. The EPN may comprise a set of any number of alphanumeric characters or symbols. The CPTI EPN corresponds to an instantiation of a class. Thus, an exchange part number (EPN) is a part number linked to a collaborative taxonomy instantiation agreed to by trading community participants. It will be appreciated that, depending on the nature of the taxonomy being used, there may be various degrees of sub-classification. Thus, a taxonomy could include sub-classes, where the instantiations fall under a sub-class.
[0170] Buyers and sellers may use the EPN in e-commerce documents within a trading community to represent products they are buying and selling.
[0171] CPTIs and EPNs may enable OEMs 208 , OEDs and CEMs 220 (FIG. 2) to easily collaborate with component manufacturers 216 and distributors 206 , 204 to quickly determine FFF equivalency. This may enable procuring entities to purchase electronic components and for sellers to more easily directly sell electronic components.
[0172] CPTI may enable CEMs 220 to rationalize multiple AMPLs and benefit from interchangeability of procured components when manufacturing products for the CEMs' multiple customers.
[0173] “collaborative taxonomy” is a catalog taxonomy created together by members of a trading community, usually starting with a base standard taxonomy (e.g., RosettaNet's RNTD, UNSPSC, eClass, BMEcat, etc.), and then deleting and/or adding classes, characteristics and values.
[0174] In contrast, the RosettaNet Technical Dictionary (RNTD) is an uninstantiated taxonomy, comprised of Classes, Property Sets, Properties, and Property Value Expressions. The RNTD has class IDs, where DRAM is a “class.” A virtually infinite number of instantiations could be generated from an RNTD class taxonomy. Manufacturers and distributors offer hundreds of variations of DRAM products, each with their own part number. Through categorization into the RNTD taxonomy, each DRAM product may generate separate instantiations, none of which might be FFF equivalent.
[0175] III. In a block 334 , an exchange operator may subsequently catalog (or categorize) EPNs, related taxonomies and instantiations into a trading exchange-based, web accessible, electronic catalog (e-catalog).
[0176] [0176]FIG. 10 illustrates an electronic catalog 1010 , which includes a taxonomy 1000 , at least one taxonomy instantiation 1002 , a search engine 1004 and at least one part number 1006 associated with the taxonomy instantiation 1002 .
[0177] The “catalog taxonomy” is the catalog's complete set of classes (a.k.a. categories) 1012 , characteristics (a.k.a. attributes or properties) 1014 , value ranges 1016 and values 1018 .
[0178] The “catalog search engine” 1004 is a software component that may (a) search the catalog's taxonomy (a.k.a. “search schema”) 1000 to find parts, prompted by user selection or specification of class 1012 , characteristics 1014 and values 1018 , and/or (b) find and display taxonomy instantiations 1002 as prompted by user selection or entry of part numbers 1006 .
[0179] Members of the trading exchange community may access the search engine 1004 and enter sets of characteristics and values for products that buyers would like to buy or sellers would like to sell. The search engine 1004 may find any EPNs that already exist for the characteristics and values.
[0180] Putting the taxonomy instantiation 1002 , and the instantiation's EPN 1006 , into an exchange catalog 1010 enables a seller/recipient of an e-commerce document (e.g., an RFQ containing an EPN) to access the catalog 1010 and display the taxonomy instantiation 1002 that correspond to the EPN 1006 . Displaying the taxonomy instantiation 1002 , which corresponds to an EPN 1006 appearing in an RFQ, may enable the seller in a buy-side hosted exchange to determine whether it has an FFF equivalent product upon which to base its response to the RFQ. A buyer in a sell-side hosted exchange can use the taxonomy instantiation 1002 as a basis to determine whether it has an IPN whose requirements may be fulfilled by a distributor or vendor who offers VPNs or MPNs with the same instantiation as the EPN.
[0181] The resulting taxonomy instantiation 1002 used in the exchange catalog 1010 may be expanded or modified as a result of each CPTI session. The taxonomy 1000 may be different than a taxonomy used in either the buy-side participants' behind-the-firewall catalog (if they have one) or the sell-side participants' catalog (if they have one). However, the resulting product taxonomy instantiation and exchange part number may be incorporated into the buy- and sell-side participants' BTF catalogs.
[0182] There may be several reasons for (I) the pre-commerce process of collaboration on the base taxonomy and (II) designation of an exchange part number (EPN) to represent the collaborative taxonomy instantiation.
[0183] Collaboration may reduce or expand or edit the classes and properties of the standard taxonomy. Version 1.4 of the RNTD contains approximately 741 classes, 2647 properties and 610 property sets. The class for DRAM includes seven property sets, and 105 properties. It may be unlikely that the range of products traded in any Private Trading Exchange (PTX) 110 (FIG. 1) would span all classes of the RNTD. For any given class, it may be unlikely that all properties of all property sets would be required to specify a given product in the PTX. It may also be likely that a given traded item might require a new class or additional properties than those available in the taxonomy before the collaboration process, which would result in the addition of a class and properties to the baseline taxonomy.
[0184] So one of the first acts in preparing for PTX e-commerce sessions may be for the trading community to collaborate on the scope of the exchange's taxonomy, based on, for example, the RNTD. Since a given PTX would likely only trade some subset of the total baseline taxonomy product array, the collaborative taxonomy may only include instantiations of certain properties within a baseline taxonomy class. The instantiations derived from the extracts represent products that are planned to be traded in the PTX.
[0185] Collaboration may expand the standard taxonomy. Buyers may want to define requirements using properties not in the baseline standard taxonomy version. Sellers may want to highlight differentiating features not reflected in the current standard. Standard taxonomies may become obsolete. Any given taxonomy may evolve. For example, the current RNTD version (2.0) is the fifth version of the dictionary. A standard taxonomy might benefit from refinement or expansion, especially between standard schema version releases.
[0186] RosettaNet has defined the RNTD as an industry standard taxonomy. But very few, if any, companies have precategorized their parts into the taxonomy to the degree necessary to determine FFF equivalence. Also, taxonomy standards will always lag the evolving technology. Selling entities in particular may feel that the standard taxonomy is not up-to-date or robust enough to accurately and completely describe what the selling entities wish to sell. However, using a standard taxonomy, like RNTD, as a baseline for collaboration in a CPTI process, would be much more productive than creating a taxonomy starting with nothing. While it requires upfront work for buyers and sellers to create a collaborative taxonomy to determine whether what a seller offers is FFF equivalent to what a buyer wants to buy via reference to collaborative taxonomy instantiation, the process may be much more efficient if the trading partners start with a baseline taxonomy, if one exists. It is reasonable to assume that the baseline RNTD for a given class, like DRAM, might be 85 to 90% as specific as it would need to be. Forming collaborative taxonomy instantiations may require up-front work by at least some of the exchange participants as a prerequisite to automated e-commerce. However, once taxonomies and associated EPNs have been established via CPTI, the problems resulting from different part numbers are solved, and buyers and sellers will no longer be constrained from engaging in fully automated e-commerce processes in the buying and selling of direct- and stockable MRO materials.
[0187] A proprietary taxonomy may be used as a competitive advantage. Enterprises or consortiums may prefer a proprietary taxonomy to enable product differentiation or to reflect newly developed technology. The enterprises and consortiums may accordingly regard the collaborative PTX taxonomy to be a source of competitive advantage. The proprietary taxonomy might be based on, or be an extension or refinement of, a standard taxonomy.
[0188] EPNs represent collaborative taxonomy instantiations. Pre-commerce collaboration enables participating companies to enter the resulting EPNs into their e-selling and e-procurement systems as material or part “master data.” The e-selling and e-procurement systems may generate and automatically process e-commerce documents, e.g., RFQs and Quotations, which contain EPNs, if the EPNs have been entered as master data in the participating companies systems. Unless EPNs are entered as master data in the trading partners systems, EPNs in incoming e-commerce documents may not be processable electronically by the receiving e-procurement and e-selling systems.
[0189] “Master data” describes data (e.g., parts, vendors, customers, prices, costs, etc.) that is predefined in e-commerce and back office systems. The predefined master data enables the systems to process transactions (e.g., entering sales orders or purchase orders) that contain part numbers. For example, if the part number 4711 has been defined in an e-selling system, and sales related master data for the material has been maintained, then the e-selling system could automatically fill in the price on a sales order after entry of the part number as a line item in the sales order. As another example, if inventory management related master data for the part has been maintained in the system, then the system could automatically calculate the availability date of the item based on information generated by applications (e.g., MRP or SCM) which use the inventory management related master data.
[0190] The availability of a standard taxonomy, like the RNTD, may provide a jump-start in developing a collaborative taxonomy, which can be modeled as a variant of a standard taxonomy.
[0191] [0191]FIG. 3B illustrates an example of using an SAP PLM System collaborative folder as an environment for the collaborative product taxonomy instantiation process as described in FIG. 3A between a buyer or procurement side 300 and one or more sellers 312 . FIGS. 3A-3B are described below with FIGS. 4-6.
[0192] Collaborative Product Taxonomy Instantiation (CPTI) (FIG. 3A) may represent a collaborative aspect of a broader process called Cross Application Product Taxonomy Management (XPTM). (FIG. 5).
[0193] [0193]FIG. 5 illustrates an example of integrating a CPTI process (white boxes) into a broader set of functions called Cross Application Product Taxonomy Management (xPTM) (i.e., xPTM includes an environment to manage the process of linking the EPN and the collaborative taxonomy into buy-side 502 , sell-side 504 and private trading exchange (PTX) applications. FIG. 5 shows CPTI and xPTM from the perspective of a procurement private trading exchange (PTX), where the EPN and the collaborative taxonomy are integrated with applications or components in buyers' and sellers' enterprise computer systems 502 , 504 . xPTM and CPTI may also be applicable in a Consortia Trading Exchange (CTX) and/or a sales private trading exchange (PTX). Stated generally, the present invention includes linking the collaborative taxonomy to back-end systems that integrate with the data or information communicated. More specifically, in xPTM, the CPTI is used to integrate the IPN (Internal Part Number) and the MPNs (Manufacturers Part Numbers), and/or VPNs (Vendors Part Numbers) that are FFF equivalent of the IPN, into the AMPL (Approved Manufacturers Parts List). The AMPL is, in turn, integrated into the following enterprise system product objects:
[0194] The BTF (Behind the Firewall) catalog, used by internal design and procurement engineers to search, find and use existing IPNs and associated AMPLs in new BOMs (Bills of Materials), where the new BOM requires a component with the same FFF as an existing IPN.
[0195] Configurable product BOMs (Bills of Materials) where the AMPL's MPNs are modeled as procurement variants in order to enable simulation in BW (Business Information Warehouse) of the effect of selecting alternative MPNs within the AMPL in terms of resulting cost and lead time of the configurable equipment, whose BOM contains the AMPL.
[0196] [0196]FIG. 5 illustrates integrating the EPN and the collaborative taxonomy into buy-side, sell-side and private trading exchange (PTX) applications.
[0197] The buy side 502 in FIG. 5 may include several software modules, such as an R/3 Materials Management (MM) module 506 , Business Information Warehouse (BW) module 508 , Supply Chain Management (SCM) module 510 , BTF catalog management/search engine module 512 , Supplier Relationship Management (SRM) module 514 , Product Lifecycle Management (PLM) module 516 , and another OTF catalog management/search engine module 518 . These modules 506 - 522 may be available from SAP.
[0198] SAP R/3 is software supporting enterprise resource planning (ERP). SAP R/3 and the other modules are described at www.sap.com.
[0199] The catalog management part of the OTF catalog management/search engine 518 may be an environment to collaboratively create a catalog product taxonomy, instantiate the taxonomy, and then categorize the resulting EPN into the catalog taxonomy. The catalog search engine is software that enables a user to find a part by specifying its characteristics or to display the characteristics of a specified part.
[0200] The PLM application 516 may be an environment to create product-related master data in an Enterprise Resource Planning (ERP) system. The PLM 516 may also provide an environment to collaboratively specify a collaborative taxonomy, taxonomy instantiations, and for generation of EPNs.
[0201] In FIG. 5, the CPTI process may include a start function 544 , a download taxonomy to collaborative-folder function 546 , a collaborate on taxonomy function 548 , a collaborative taxonomy (c-tax) file and folder 550 , which holds the taxonomy, a create EPN for c-tax function 552 , a catalog EPNs to c-tax function 554 and a resulting catalog of EPNs 556 . All other functions shown in FIG. 5 may be Cross Application Product Taxonomy Management (xPTM) or enterprise system or e-selling or e-procurement functions. The PLM 516 c-Folder components and exchange-based catalog management/search engine 518 may be accessible outside the firewall (OTF) of the buy side enterprise system, on the exchange.
[0202] [0202]FIG. 6 illustrates the Cross Application Product Taxonomy Management (xPTM) process of FIG. 5 with a view of user roles. The following scenario describes CPTI used in a procurement Private Trading Exchange (PTX), where the buying company 300 may seek additional sources of supply for a strategic component (e.g., DRAM).
[0203] In a block 546 in FIG. 5 (block 616 in FIG. 6), a buy-side procurement engineer 302 (FIG. 3B) secures or downloads a taxonomy to be used as a baseline taxonomy for collaboration. For example, the spreadsheet version of the RosettaNet RNTD, version 1.4, may be downloadable from www.rosettanet.org. The buy-side procurement engineer 302 specifies relevant DRAM attributes among attributes provided by the baseline taxonomy 304 and specifies values for the specified attributes.
[0204] In a block 548 , the buy-side 502 and the sell-side 504 collaborate on a taxonomy. In blocks 604 , 606 and 616 of FIG. 6, the design engineer and procurement engineer may specify a schema attribute range and collaborate 620 with a sell side 602 product manager on a taxonomy instantiation. The buy-side procurement engineer 302 (FIG. 3B) publishes the baseline taxonomy with specified relevant DRAM attributes 308 on the web 311 via secure communication 307 with extensible Markup Language (XML) or xCBL. xCBL is an XML variant. XML is a technique to format a document in a way that it can be read if processed by a computer. There are many XML variants.
[0205] In one configuration, the engineer 302 may use an SAP Product Lifecycle Management (PLM) collaborative folder (c_folder) 306 , which is currently available from SAP, or a web-enabled collaborative catalog maintenance environment. The PLM collaborative folder 306 is a web accessible folder where documents can be stored, accessed and modified by trading partners. The folder 306 may be used for collaborative configuration and classification schemas. Storing the published baseline taxonomy with specified relevant DRAM attributes 308 in a c-folder 306 enables sellers 312 to access and process (expand, reduce) the baseline taxonomy.
[0206] One or more sellers 312 may specify attributes of their DRAM product offerings in the collaborative taxonomy 304 . The sellers 312 may want to specify attributes not originally included in the baseline taxonomy. A seller may have developed a product feature not yet in existence when the baseline taxonomy was created. The seller 312 adds the attribute representing the product feature to the buyer-specified collaborative taxonomy stored in the c-folder 306 which the procurement engineer 302 can also access.
[0207] In blocks 606 , 618 , 620 of FIG. 6 (and block 548 in FIG. 5), a buy-side design engineer and/or the procurement engineer 302 and a sell-side product manager collaborate on taxonomy characteristics and values.
[0208] After collaboration, the procurement engineer 302 evaluates the sellers' specified attributes, rationalizes these with the buyer provided attributes and specifies a resulting collaborative taxonomy (c-tax) instantiation 550 . In a procurement exchange, the procurement engineer 302 may finalize the collaborative taxonomy instantiation, which may include additions or changes to the buyer-published initial collaborative taxonomy as provided by one or more sellers 312 . The procurement engineer 302 may decide to manage revisions to the collaborative taxonomy instantiation by creating corresponding versions or revision levels with PLM. In a sales market exchange, the process may be the same except that the initial instantiation and collaborative taxonomy instantiation finalization and revision is performed by the seller, with buyers proposing modifications. In a public market exchange FIG. 8 the marketplace 802 administrator may provide the initial instantiation and collaborative taxonomy instantiation finalization and revision, with both buyers 800 and sellers 804 proposing modifications. Using the DRAM RNTD example above, an example of a collaborative taxonomy instantiation may be derived:
[0209] RosettaNet Class=“XJA644” (DRAM)
[0210] Technology=“CMOS”
[0211] Voltage [min]=“1.1”
[0212] Voltage [max]=“5.5”
[0213] Rated Maximum Power=“GT 4 AND LT 6”
[0214] Operating Temperature [min]=“45”
[0215] Operating Temperature [max]=“50”
[0216] Is Generic=“1”
[0217] Pin Count [min]=“20”
[0218] Pin Count [max]=“24”
[0219] In a block 524 (FIG. 5) (block 608 in FIG. 6), a design engineer on the buy side 502 may create one or more Internal Part Numbers (IPNs) or IPN material masters.
[0220] In a block 534 (block 610 ), the design engineer may catalog IPNs to the collaborative taxonomy (c-tax) instantiation, i.e., link an IPN to the class, attributes and values of the c-tax.
[0221] In a block 612 , the design engineer optionally uses Product Lifecycle Management (PLM) to create a version or revision level of the c-tax document 550 .
[0222] In a block 536 (block 614 ), the design engineer specifies category attribute values of the IPNs and uses the c-Tax and IPNs to create an Approved Manufacturers Parts List (AMPL) structure.
[0223] In a block 564 (block 622 ), the sell-side product manager catalogs MPNs or VPNs to the c-Tax instantiation.
[0224] In a block 552 , the design engineer or procurement engineer 302 generates, designates or specifies an exchange part number (EPN), e.g., “4711,” to represent the collaborative taxonomy instantiation. Thus, an exchange part number (EPN) is correlated with a collaborative taxonomy instantiation. The part number may be a sequentially assigned number or may be a part number designed to be recognizable as correlating to the instantiation (sometimes know as an “intelligent” part number). The procurement engineer 302 may catalog an IPN as an EPN or generate a separate EPN.
[0225] In a block 554 , the procurement engineer 302 catalogs the EPN into an exchange catalog 1010 (FIG. 10) to produce a catalog 556 of EPNs 1006 . An exchange catalog search engine 1004 may use the collaborative taxonomy 1002 as the catalog search schema/taxonomy. The exchange catalog search engine 1004 allows users to specify or select attribute values from the C-tax 1000 , which triggers the search engine 1004 to retrieve and display EPNs that have the specified attributes.
[0226] The collaborative taxonomy 1002 enables trading partners 302 , 312 to find EPNs where the desired form, fit, function (FFF) is known, but the corresponding EPN is not. For example, if a trading partner 312 wants to promote a product for sale or generate a sales quotation in response to an RFQ, but does not know whether collaboration has already occurred or whether a useable EPN already exists, the sell side trading partner would like to find out the attributes and values of an EPN. In another example, a seller may want to know whether there is a part in the catalog 1010 where the part is a DRAM component, with CMOS technology, with minimum voltage or 1.1, etc. The catalog search engine 1004 would find the part based on the user specification or selection of these attributes in the catalog.
[0227] The collaborative taxonomy 1002 enables trading partners 302 , 312 to find the taxonomy instantiation where the EPN is known but the associated form, fit and function (FFF) are not. For example, if a supplier received an RFP/RFQ for “4711,”and wants to determine the associated FFF, the supplier can enter the EPN 4711 into the catalog search engine prompting the catalog to display the attributes and values of 4711. If the EPN had already been cataloged into the supplier's BTF catalog, the supplier would know the EPN and taxonomy instantiation. However, the supplier might not know the EPN in a scenario, for example, where the supplier is a new member of the trading community and was not able to participate in the original collaboration process.
[0228] [0228]FIG. 4 illustrates an example of multiple buy-side systems 402 and sell-side systems 406 that map an exchange part number (EPN 4711) to FFF equivalent BTF part numbers. In FIG. 4, buyers 408 A- 408 C and sellers 418 A- 418 C may integrate the EPN into their respective enterprise computer systems by mapping the EPNs to their respective FFF equivalent IPNs, MPNs and VPNs.
[0229] In FIG. 4, the EPN 4711 has been mapped to the Internal Part Numbers (IPNs) 1234 and 7890 on the buy side 402 and to the MPNs ABCD and EFGH and the VPN WXYZ on the sell side 406 . This mapping enables the respective enterprise systems on the buy and sell sides 402 , 406 to automatically translate to and from their respective IPNs, during generation of purchasing documents, and MPNs and VPNs, during generation of sales documents. FIG. 4 also illustrates use of the EPN 4711 by the exchange-based systems 412 , for example, for demand aggregation 414 A, generation of Request for Quotations (RFQs) 414 B, and auctioning/bidding 414 C.
[0230] Once the collaborative taxonomy 1000 , the collaborative taxonomy instantiation 1002 and associated EPN 1006 have been established, operators of a procurement PTX may use (a) the collaborative taxonomy 1000 as a search schema in the catalog 1010 to search for part numbers with FFF specified by the taxonomy instantiation; (b) the EPN 1006 in RFQs to communicate to sellers the FFF requirements of the products to be procured (the recipients can enter the EPN 1006 in the exchange catalog 1010 to display the EPN's taxonomy instantiation 1002 ); (c) and the EPN 1006 in the exchange auctioning and bidding system, DA/DB; (d) the taxonomy instantiation 1002 in an AMPL, in order to specify the FFF parameters by which the IPN, MPNs and VPNs within the AMPL are grouped.
[0231] The technique of CPTI and the resulting EPNs may be used to enable automated translation from several different IPNs on the buy (demand) side into a single, common EPN, which can be used by multiple PTX applications, such as demand aggregation 414 A (FIG. 4), auctioning and bidding 414 C, the generation and transmission of RFQs 414 B, and the translation of EPNs in RFQs received by multiple sell side systems into MPNs and VPNs within the sellers' systems.
[0232] On the procurement side 402 , 502 , a buyer 408 may model the EPN as a manufacturer's part number (MPN), which is linked to a buyer's internal part number (IPN) via an approved manufacturers parts list (AMPL) 410 A or a purchasing information record 410 C. As a result, purchasing documents generated by the buyers 408 A- 408 C may contain both the IPN and the EPN. The EPN is recognizable by the sellers' systems if the seller's system (which may have participated in CPTI) can search the EPN in an exchange catalog or the seller's system has modeled the EPN as a Customer Part Number (CPN). Additionally, the sell-side systems generally may be able to automatically translate the EPN, modeled as a CPN, into the sellers° FFF equivalent MPN or VPN
[0233] In a block 540 (block 628 ), the procurement engineer on the buy-side 502 may enter an EPN into an auctioning and bidding application 414 C (FIG. 4).
[0234] An Approved Vendors List (AVL) can refer to the same function as defined above for AMPL.
[0235] On the sales side 406 , 504 , in a block 558 (block 624 ), the sales engineer or product manager either (a) engages in a CPTI process, and takes the resulting EPN, or (b) selects EPNs of interest resulting from earlier CPTI sessions from the exchange opportunity catalog 556 , and enters/maps/model an EPN as a customer part number (CPN). The CPN may be linked to a seller's MPN or VPN. Boxes 416 A- 416 C in FIG. 4 show EPNs modeled as CPNs. The EPN-modeled-as-CPN may automatically translate into a seller's Internal Part Number (IPN). The IPN may be a MPN, if the seller is a manufacturer 418 A or 418 B. The IPN may be a Vendor Part Number (VPN), if the seller is a distributor 418 C. The EPN-modeled-as-CPN enables the recipient's e-selling or enterprise system to automatically translate an EPN received in an RFQ into the seller's MPN or VPN. In a block 560 (block 626 ), the seller may respond to auctioning and bidding system generated RFPs and RFQs.
[0236] In a block 538 (block 628 ), the procurement engineer may enter the EPN or MPNs or VPNs selected as a result of an auctioning and bidding process into an AMPL or AVL for the buyer's IPN.
[0237] [0237]FIG. 8 illustrates a market exchange scenario with buyers 800 , a marketplace 802 and sellers 804 that use exchange part numbers (EPNs). In blocks 806 and 830 , buyers 800 and sellers 804 collaborate (i.e., expand or reduce) on an exchange schema and generate product taxonomy instantiations. The market exchange operators may control the marketplace 802 , which may be a web site. In a block 814 , the market exchange operator manages the exchange taxonomy (catalog schema) and taxonomy instantiations resulting from the buyers' collaboration 806 and the sellers' collaboration 830 on the baseline taxonomy, (e.g., the UNSPSC, eClass or RNTD, etc. taxonomy) in the marketplace 802 . In a block 816 , the exchange operator 802 creates exchange product numbers (EPNs) and posts the EPNs as net changes to the marketplace/exchange catalog.
[0238] In a block 808 , the buyers 800 classify buyer's internal part numbers (IPNs) into the buyer's BTF catalog schema/taxonomy. In a block 818 , the marketplace 802 operator publishes catalog updates or changes, which can be downloaded to buyers' or sellers' BTF catalogs. In a block 832 , the sellers 804 classify vendor part numbers (VPNs) (which could also be called MPNs) into a supplier's BTF catalog schema/taxonomy. In a block 834 , the sellers 804 create a VPN/EPN link, e.g., where the EPN is modeled in a Sales and Distribution (SD) system as a Customer Part Number linked to a VPN.
[0239] In a block 810 , the buyers 800 create a buyers' internal part number to EPN link, e.g., in an SAP Materials Management (MM) Purchasing Information Record or AMPL. In a block 812 , the buyers 800 generate a forecast of requirements for the buyers' internal part number. When a buyer sends the forecast requirements to the market exchange, the buyer's system translates the buyer's internal part number into the EPN. In a block 820 , the marketplace operator or a marketplace-based system 802 aggregates all forecasts for the same EPN (coming perhaps from different buyers) in the marketplace systems environment 802 . In a block 822 , the market exchange operators 802 may conduct an auction and generate an RFP or an RFQ. In a block 836 , the sellers 804 check their availability status (also known as Available to Promise (ATP)) for their part number that is equivalent to the EPN in the RFP/RFQ document. In a block 838 , the sellers 804 may produce a proposal or quotation sales document to send to the buyers 800 either directly or via the exchange 802 .
[0240] [0240]FIG. 9 illustrates a schema (a.k.a. taxonomy) instantiation-based part number generation approach to multiple part numbers. All buy-side and sell-side participants may use EPNs. Buy-side systems that are on-ramps to the Market or Marketplace Exchange may map buyers' internal part numbers (BPNs) with EPNs. One or multiple buy-side systems may have more than one buyer internal part numbers for parts that are FFF equivalent. In this case, buyers separately map the FFF BPNs to the same FFF equivalent EPN. Examples of functions within a buy-side-of-the-exchange procurement system enabling BPN-to-EPN mapping are Purchase Information Records and Approved Manufacturers Parts List (AMPLs), as provided within SAP's R/3 Enterprise system. Most buy side systems may have similar functionality. Sell-side systems may map their internal seller part numbers (which may be MPNs if the seller is a manufacturer, or VPNs, if the seller is a distributor) to the EPN, where the EPN is entered as a Customer Part Number (CPN). An example of a function within a sell-side system enabling EPN to SPN mapping is the Customer Information Record, as provided within the R/3 Enterprise system. Most sell side systems may have similar functionality. With the customer info record, the EPN would be modeled as a Customer Part Number (CPN).
[0241] A buyer 900 may have different divisions or have acquired a company or companies, which can result in the buyer using different part numbers BTF for FFF equivalent items. For example, the buyer might link in separate purchasing information records or separate AMPLs Buyer Part Number A (BPNA) 906 A and BPNB 906 B to the same EPN 1 . This internal mapping results in the buyer's system automatically translating the buyers internal part numbers, for example, BPNA 906 A and BPNB 906 B, to the same EPN, for example, EPN 1 . A marketplace 902 uses an EPN, for example EPN 1 , which is a FFF equivalent to a Supplier Part Number Z (SPNZ) 910 . Parts traded on the exchange require different EPNs, for example EPN 1 , EPN 2 , or EPN 3 , when the EPNs have different FFF, as specified by different corresponding taxonomy instantiations. EPN 2 912 is a FFF equivalent to BPNC 914 , SPNY 916 A and SPNX 916 B. EPN 3 is a FFF equivalent to BPND 920 and SPNW 922 .
[0242] As a result of the technique of modeling FFF equivalent EPNs and linking these to IPNs in the buy-side systems purchasing info records or AMPLs (or the buy side system's equivalent functionality), exchange based systems, for example demand aggregation 414 A (FIG. 4), can use a single part number, the EPN, because the on-ramp procurement systems automatically translate their IPNs to EPNs on commerce documents sent to the market exchange environment. The technique of CPTI with resulting EPNs enables the same, universally understood EPN to appear on all commerce documents, for example purchase orders (POs) and sales orders (SOs). Just as the buy-side procurement systems translate from IPNs to EPNs in outbound e-commerce documents through standard purchasing information records or AMPLs, the EPNs are translated to sellers' part numbers (SPNs) on inbound commerce documents, through standard customer information record functionality. FIG. 11 illustrates a bill of materials (BOM) structure 1100 for a parent item 1102 and an AMPL 1124 for a component 1112 of the parent item 1102 . In one example, the BOM structure 1100 may be implemented behind-the-firewall by SAP R/3.
[0243] Thus, as shown above, the technique of CPTI and the Exchange Part Number (EPN) may serve as a semantics lynchpin in the supply chain by restoring the semantic disconnect resulting from buyers and sellers having different, mutually incomprehensible part numbers for items which are FFF equivalents.
[0244] Although mySAP enterprise system examples are shown and described above, CPTI could be integrated in a network of heterogeneous e-selling and e-procurement and enterprise computer systems. E-selling and e-procurement and Enterprise computer systems generally allow users to establish links and automatic conversion between internal part numbers (IPNs) and trading partners' part numbers. An example is the AMPL (Approved Manufacturers Parts List), where a user has linked an IPN for a component with several approved part numbers, including VPN 1 1126 A, MPN 1 1126 B, and EPN 1 1126 C (FIG. 11). After the user establishes the link in the AMPL 1124 , the buyer's procurement system can “translate” the buyer's IPN into a seller's part number 1126 A or 1126 B or an EPN 1126 C in purchasing documents sent to the seller. Another example is a purchasing information record that links an IPN with a vendor master record. Enterprise systems generally have equivalent functionality that works on both the buy side and the sell side.
[0245] However, to enable the buyer to populate the AMPL 1124 or a purchasing information record, or the seller to populate a customer information record, the buyer and seller have to communicate to determine that a buyer's IPN is an FFF equivalent to the seller's MPN. Without the CPTI process or an equivalent process where additional information is exchanged between buyers and sellers, neither buyer nor seller would be able to establish the link (or map) between their respective IPNs, VPNs and MPNs. Therefore, the automatic translation could not occur without CPTI or without some less efficient, less automated information exchange.
[0246] With CPTI, buyers may populate either the AMPL or the purchasing information record with the Exchange Part Number (EPN). Sellers would populate the customer information record, or their systems' equivalent function, with the EPN. The respective buy-side and sell-side systems would be able to automatically translate from the buyers' IPN to the EPN and from the EPN to the sellers' IPN, i.e., MPN or VPN.
[0247] A catalog content maintenance environment may be a software component that can create catalog content by maintaining a taxonomy 1000 (FIG. 10) and linking parts to taxonomy instantiations 1002 . Taxonomy maintenance may refer to selection or specification of (a) classes 1012 to be included in a catalog 1010 , (b) characteristics 1014 to be included in classes, and (c) values 1018 or ranges of values 1016 to be valid for characteristics 1014 .
[0248] A “product taxonomy instantiation” is a taxonomy instantiation linked to a product (a.k.a. part).
[0249] Enterprises that utilize e-commerce technology (e-selling, e-procurement, public and private market exchanges) may have a large potential return on investment (ROI) when using e-commerce technology products to buy and sell direct and stockable MRO materials. However, the potential ROI in these technology products may not be fully realized if the e-commerce processes are not fully automated, but rather require participation of sales and procurement engineers to determine whether materials being traded are FFF equivalent.
[0250] The principles of CPTI may be applied to any manufacturing industry, such as semiconductors, computers, automotive, aerospace, defense, consumer goods, oil & gas, and apparel. Many industries are developing industry-specific taxonomies, which are useable as base taxonomies for CPTI. These industries may have direct materials and/or stockable maintenance, repair and overhaul (MRO) materials. The CPTI process may enable customers to realize significant ROI in stockable MRO and direct materials sales and procurement environments.
[0251] CPTI may be used by procurement engineers in purchasing companies, by sales engineers in selling companies and by operators of PTXs (Private Trading Exchanges).
[0252] A number of configurations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the application. Accordingly, other embodiments are within the scope of the following claims.
ACRONYMS
[0253] AML—appoved manufacturer's list
[0254] AMPL—approved manufacturer's parts list
[0255] ATP—available-to-promise
[0256] AVL—Approved Vendors List
[0257] BOMs—bill of materials
[0258] BTF—behind the firewall
[0259] BW—Business Information Warehouse
[0260] CEM—contract electronics manufacturer
[0261] CMS—contract manufacturing services
[0262] CPN—customer part number
[0263] CPTI—collaborative product taxonomy instantiation
[0264] CPTM or c-PTM—collaborative product taxonomy management
[0265] CRM—customer relationship management
[0266] c-Tax—collaborative taxonomy
[0267] CTX—consortia trading exchange
[0268] CW—content workbench
[0269] DAB—dynamic auctioning and bidding
[0270] DB/DA—dynamic bidding, dynamic auctioning
[0271] EBP—Enterprise Buyer Professional
[0272] EMS—electronic manufacturing services
[0273] EPI—exchange part identifier
[0274] EPN—exchange part number
[0275] ERP—enterprise resource planning
[0276] FFF—form, fit, function
[0277] GTIN—global trade item number
[0278] IPC—Internet pricing and configurator
[0279] IPN—internal part number
[0280] IPC—SAP's Internet Pricing and Configuration
[0281] KB—Knowledge Base
[0282] MM—SAP R/3 Materials Management
[0283] MPN—manufacturer's part number
[0284] MRO—Maintenance, Repair and Operations
[0285] MRP—Materials Requirements Planning
[0286] ODM—original design manufacturer—OEMs who no longer manufacture “in-house,” but rather outsource manufacture of designed equipment to CEMs (Contract Electronics Manufacturers).
[0287] OED—Original equipment designer
[0288] OEM—original equipment manufacturer
[0289] OTF—outside of the firewall
[0290] PEX—private exchange
[0291] PIPs—RosettaNet Partner Interface Processes
[0292] PLM—product lifecycle management
[0293] PM—plant maintenance
[0294] PO—purchase order
[0295] PPV—Purchase Price Variance
[0296] PTX—private trading exhange
[0297] RFP—request for proposal
[0298] RFQ—request for quotation
[0299] RNTD—RosettaNet Technical Dictionary
[0300] ROI—return on investment
[0301] ROH—raw or purchased
[0302] SCE—sales configuration engine
[0303] SCM—supply chain management
[0304] SD—Sales and Distribution
[0305] SFA—sales force automation
[0306] SO—sales order
[0307] SRM—Supplier Relationship Management
[0308] VAD—value added distributor
[0309] VPN—vendor's part number
[0310] xApp or X-App—cross application
[0311] XML—eXtensible markup language
[0312] xPTM—cross-application Product Taxonomy Management
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A method forms a collaborative product taxonomy instantiation by starting with or defining a base taxonomy instantiation and collaborating between trading parties to negotiate a collaborative product taxonomy instantiation. The taxonomy instantiation comprises a set of characteristics and values of a desired product. The method assigns a set of characters to the collaborative product taxonomy instantiation. The method uses the set of alphanumeric characters in an electronic trade exchange between a buyer software application and a seller software application. The seller software application may determine whether it has a product that is equivalent to the collaborative product taxonomy instantiation.
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This application claims benefit of provisional application Ser. No. 60/026,238 filed Sep. 17, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a parachute flight training simulator and more particularly to such a simulator in which the trainee provides input signals to a programmed computer and observes a computerized display simulating his flight.
2. Description of the Related Art
Parachuting simulation systems are described in U.S. Pat. No. 4,737,107 issued Apr. 12, 1988 to Bories et al. and U.S. Pat. No. 4,264,311 issued Apr. 28, 1981 to Call, et al. Both of these systems involve mechanical systems wherein the parachutist is suspended from a frame and mechanically moved in a manner simulating a parachute flight. There is no suggestion of the simulation of a flight by a pictorial display which the parachutist observes and can control his parachute to provide a simulated landing in a desirable spot and in a matter to avoid colliding with other parachutists.
Simulation systems are used extensively for training pilots in flying conventional fixed wing and rotary wing aircraft. In such systems, students are seated in replicas of aircraft cockpits, moving force-loaded controls to simulate flying in response to movement of displayed elements in electronically generated scenes. Flight simulation systems of this type are described in U.S. Pat. No. 4,016,658 issued Apr. 12, 1977 to Porter, et al; U.S. Pat. No. 4,078,317 issued Mar. 14, 1978 to Wheatley, et al; and U.S. Pat. No. 5,017,141 issued May 21, 1991 to Relf, et al. To the best of applicants' knowledge, however, simulation systems having displays which simulate the flight pictorially from beginning to end are not found in the prior art for parachuting flight training.
SUMMARY OF THE INVENTION
The system of the present invention provides a simulated parachute flight in which the parachutist has a video display to watch which shows objects on the ground in three dimensional form as well as other parachutists in the vicinity. The display is controlled by a computer which effects changes in the display as the parachutist "descends" and accounts for action by the parachutist in using controls and shifting of weight to change the path of the parachute.
In one embodiment of the invention, the parachutist is suspended in a harness from a pulley system. The pilot has control toggles. When these toggles are actuated, an electrical signal is generated in response to such movement which is fed to a computer for processing. A separate electrical signal is sent to the computer in response to motion and change of force on the harness riser straps due to body movement by the parachutist.
The computer is programmed to generate control signals in accordance with dynamic flight features, head motions of the parachutist, a simulation of the objects on the ground, and the flights of other parachutists in the vicinity. The output of the computer is fed to a 3-D graphics adapter which generates 3-D control signals from the computer signals, these signals being fed to one or more computer monitors, projectors, or a display mounted on the head of the parachutist for display. A separate output is fed through a standard display adapter to a monitor used by the instructor. The instructor has a keyboard, mouse, and joysticks at his disposal to provide control signals into the computer for varying the flight conditions.
It is therefore an objection of this invention to provide an improved simulation system for training parachutists.
It is a further object of this invention to facilitate the training of parachutists by providing a simulated descent which is displayed on computer monitors, projectors, or a head mounted display in real life form.
Other objects of the invention will become apparent in view of the following description taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram showing the basic features of a preferred embodiment of the invention;
FIG. 2 is a schematic illustration showing a harness and support device which may be employed in supporting the parachutist in the preferred embodiment.
FIG. 3 is a schematic illustration of a force control loader which may be utilized in the preferred embodiment;
FIG. 4 is a view taken along the plane indicated by 4--4 in FIG. 3;
FIG; 5 is a view taken along the plane indicated by 5--5 in FIG. 3; ad
FIG. 6 is a flow chart illustrating the operation of the system of the invention;
FIG. 7 is a flow diagram illustrating the real time parachute dynamics of the system of the invention;
FIG. 8 is a flow diagram illustrating the real time rendering loop of the system of the invention;
FIG. 9 is an overall flow diagram of the system of the invention;
FIG. 10 is a flow diagram illustrating program startup in the system of the invention; and
FIGS. 11A and 11B are flow diagrams illustrating options available in the system of the invention during and after the parachutist's jump.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a simplified block diagram of the preferred embodiment of the invention is shown.
In one embodiment of the invention, the student parachutist wears a harness and is suspended from a support frame 52 by means of a pulley system, as shown in FIG. 2.
A pair of control toggles simulating those in a regular parachute are provided. The action on these control toggles is sensed by Parachutists Action Sensors 1 which provide an electrical signal output in accordance with such action. The output of sensors 1 is fed to computer interface 7, the digital output of which is fed to computer 27.
Body motion of the student parachutist effecting force changes on the harness riser straps, which would affect the movement of a flying parachute, are sensed by Parachutists Force-Position Sensors 2 which provide electrical output signals. These signals are fed to computer 27 through computer interface 9. It is to be noted that the sensors employed may include potentiometers, optical encoders or may have digital outputs so as to obviate the need for an analog-digital converter.
Computer 27 processes the signals it receives and, as to be explained further on in the specification, is programmed to provide signals representing a simulated flight, including simulated scenes such as pictorial representations of the ground (shrubbery, roads buildings, etc.), as well other tutorial aids such as representations of winds and trajectories and simulated flights of other parachutists.
The output of computer 27 is fed to 3-D Graphics Adapter 28 which converts the signals to represent images in 3-D form. Such a 3-D Adapter may comprise a model XL-100 unit available commercially from 3Dfx Interactive Co. The output of the 3-D Graphics Adapter 28 is fed to Parachutists Display Device 3, which provides a pictorial 3-D display to the parachutist, simulating what would appear in an actual parachute descent.
An output from the computer 27 is also provided to Standard Display Adapter 32 where the signals are processed for providing a display on the Instructor's Display Monitor 4. Using this monitor, the instructor can employ the Instructor's Control 50 to enter signals into the computer to modify the flight parameters, as may be desired.
Referring now to FIGS. 2-5, the mechanisms are shown by which signals generated by the student parachutist are processed. It is to be noted that only the mechanisms on one side (in the example, on the rights side of the parachutist) are illustrated, there being mechanisms on the opposite side which are identical.
The parachutist's harness is suspended from support frame 52 by means of riser straps 54. The riser straps are connected to the support frame through support lines 58 and pulleys 6. Force measuring devices such as load cells 56 are placed in series between the riser straps and the support lines. These load cells sense force on the straps and provide electrical output signals in accordance with such force for processing in the computer.
Parachute cord control line 8 simulates the control line of a parachutist in controlling flight. Cord 8 runs through pulley 10 to the controller 24 illustrated in FIGS. 3-5.
As can be seen in FIGS. 3-5, cord 8 is fed through guide hole 15 and wrapped around reel 14. Clamp 17, which is attached to cord 8 limits retraction of the cord. Soft stop member 18 and resilient cushion 19 are provided to cushion strong sudden pulls on the cord. Shaft 20 is attached to the flange 21 of the reel and rotates therewith.
The shaft of potentiometer 22 is connected to shaft 20 so as to rotate therewith and provide a resistance variation in accordance with such motion. A reference voltage is applied across the potentiometer to provide an electrical output in accordance with the resistance variation. In lieu of a potentiometer, a digital encoded position sensor or optical encoder may be employed.
Cord 8 is preloaded on reel 14 by spring loading the reel with a coil spring connected between the reel and its casing or by means of a torque motor. The signals from the potentiometer are converted to digital form and fed to the computer for processing.
Referring now to FIG. 6, a flow diagram showing the operation of the system of the invention is presented. The student parachutist effects release of the main canopy by pulling on the parachute main release handle 42. As the cable connected to the handle is drawn, it trips microswitch 43 simulating the release of the parachute. In lieu of a microswitch, an optical sensor may be employed. If a canopy malfunction is selected in the exercise and the student pulls on the main cutaway control 44 or reserve release control 45, switches 46 and 47 are tripped. If no student malfunction signal is generated, and automatic opening of the parachute has been selected, the system will simulate automatic canopy deployment. The simulated successful opening of the chute or the malfunction failure result is displayed on the video display device as an appropriate canopy simulated motion. The signals from switches 43, 46 and 47 are converted to digital form in the digital signal computer interface and fed to the computer 27.
When the parachutist pulls on the riser straps 54 (See FIG. 2) or shifts weight, this is sensed by force or force/position sensors 25 which provides an output signal in accordance with the input received to analog signal computer interface 26. The signals are converted to digital form in this interface and fed to computer 27. When the student pulls on one or both of the control toggles connected to line 8 (see FIG. 2), this is sensed by force loaded position sensors, converted to digital form in a computer interface and fed to the computer 27. Head motions of the parachutist are sensed by head motion tracker 49, converted to digital forming a computer interface and fed to the computer. Signals to and from other simulators are fed through Network Adapter 62.
A keyboard, mouse and joysticks 50 are provided for the instructor to provide a control input into the computer. With these controls, the instructor can modify the displayed scene, use a cursor pointer to demonstrate to the student and move the effective position of the student's eye point in pitch and yaw when the student is using the tipped ground monitor rather than a head mounted display. When the parachutist is provided with a fixed monitor display of the simulated scene, the scene can be optionally oriented by the instructor using the joystick or using logic which supplies tips in pitch and roll as a function of attitude; as biases towards the target area with boot symbols displayed on the monitor moving to indicate the down direction and changing color or to outline at the edge of the screen if their computed location would be off screen. A joystick can also be used by the instructor during a playback of a previous jump to move the student's eye point around center while decreasing or increasing the distance from the jumper at the same time as the parachute is extracted.
Display outputs are fed from the computer to a 3-D Graphics display adapter where 3-D video display signals are generated. These signals are fed to two monitors one or the other of which the student parachutist uses. One of these is a tipped ground plane display monitor 31 and the other is a head mounted display monitor 48. The head mounted display monitor is capable of sensing the view at three head rotation angles which has the advantage of affording a view of simulated canopy malfunctions overhead and other jumpers normally out of view in a normal video display. A standard display is fed to the instructor's monitor 30.
Hard disk data storage 29 is provided for the computer. Speakers are provide to provide sound simulation for the parachute jump generated in the computer. A network adapter is also provided to permit the coupling of other simulators into the system.
Referring now to FIG. 7, a flow chart is shown which illustrates the real time parachute dynamics of the system of the invention, as programmed into the computer.
One core element of the real time simulation is the parachute dynamics loop. The functions that comprise this loop are executed once for each frame of graphics, typically 30 or 60 Hz. The contents of this code is shown graphically in FIG. 7. There are three main inputs required for the dynamics code, i.e. control inputs, X1; atmospheric conditions, X2; and current parachute state. The control inputs are the states of the toggle lines and parachute instrumentation.
The atmospheric conditions of concern are the wind and gust velocities in three dimensions as well as the air density. These parameters are stored in a volumetric table look-up that is queried with the current position of the parachute. The parachute flight state contains information required to calculate forces and moments on the parachute. Important quantities include body axis velocities, u, v, and w, body axis rates p, q, and r, and body orientation alpha and beta. These flight state parameters are the outputs of the previous iteration of the dynamics loop.
The force and moment equations, X3 use the three sets of inputs and user chosen parachute model to determine the parachute's applied forces, Fx, Fy, and Fz and moments, Mx, My, and Mz. Once the force and moments have been determined, the body axis linear and angular accelerations can be calculated from well known rigid body equations of motion. These equations relate accelerations to inertia values, X4 and body axis inertial rates The resulting body axis linear accelerations, u-dot, v-dot, and w-dot and angular accelerations, p-dot, q-dot, and r-dot are then numerically integrated (X5) to yield the body axis rates, u, v, w, p, q, and r.
The real time numerical integrator derives its time step value by subtracting the current system time from the system time at the previous iteration. This time is accurate to one clock cycle of the computer clock (typically 6 nanoseconds). The body axis rates are then transformed via a well known coordinate transform, X6 into the inertial rates Vx, Vy, Vz, psi-dot, theta-dot, and phi-dot. These rates are then numerically integrated, X7 to yield the parachute position and orientation in inertial space. The rendering engine, X10 uses this position to place the parachutist's eye point in the virtual scene. The dynamics loop uses this position and the values from which it is calculated as an input for the next iteration.
Referring now to FIG. 8, a flow chart illustrating the real time rendering loop of the system of the invention is shown.
A second core feature of the parachute maneuvering simulator of the system of the invention is the scene displayed to the parachutist jumper. Perspective transformation computations convert a virtual scene populated with three dimensional models into two dimensional polygons that are then displayed by the hardware graphics card. This can be achieved, for example, by using equations available in a standard 3-D graphics textbook. FIG. 8 illustrates the function of the code used to drive this rendering engine.
The jumper's location and head orientation are used to place the renderer's virtual eye point (Y1). The location is determined as a result of the dynamics calculations and the head orientation is the output of the head tracking system. Based on the user's preference, this head tracker could either be a head mounted sensor, a joystick simulating head motion, or automated logic that moves the parachutist's virtual head in an attempt to keep the landing site in view. Once the eye point has been determined, the jump partners model locations are updated (Y2) if the jump includes partners. The partners positions are determined by saved information from other jumper trainees (Y5) or network simultaneous jumper trainees. Next the scene's Wind indicator is articulated (Y3) based on the current atmospheric conditions at the landing site. These conditions (Y6) are calculated by the dynamics loop.
Once the positions of the jumper, his jump partners, and the wind indicator are updated, collision detection (Y4) is performed. The position and extent of the jumper model is compared with all other models in the scene. If an intersection has occurred then a determination must be made is the intersected object was landable upon (as in the case of the ground or a flat building roof) or not (as in the case of a tree or building side or peaked rooftop). If the object was landable upon, the run is ended and a score given for the overall jump. If the object was not landable upon, the run is ended and the jumper is informed that a collision has taken place. If no intersections occur at all, then the rendering engine is called to update the scene and render a new frame of graphics (Y10). Once called, the rendering engine fills the hardware frame buffer, displays it, and waits for the next update (Y11).
Referring now to FIG. 9, a flow chart is shown which illustrates the overall operational program flow logic of the system of the invention.
At the start of the program, the instructor must choose from a number of options (A1), including one of loading a previously stored run (A2). If a new run is chosen, the instructor then makes a number of run startup choices (A1). Once this has been done, the instructor can start the jumper on a simulated parachute jump for training, practice, rehearsal, or entertainment (A3). During the run, the instructor can change a number of training display options, pause or terminate the run. After the run, the instructor has a number of jump evaluation options, including using the computer's run storage to keep or load runs (A5), see the run from a number of different perspectives (A6), see and print out maps, start a new run (A7), or end the program.
Referring now to FIG. 10, a flow diagram is shown illustrating the start logic flow of the system of the invention. This program can optionally be configured to require a password (A8). Next, the instructor chooses a particular parachute to be simulated (A9). The next choice is whether to make a new run, review any previously recorded runs, or use any previous settings in making a new run (A10). If a new run is to be reviewed, this is organized by wind scenarios (A11).
The jumpers name (A12) and weight (A13) can be entered, followed by the location of the individual target location (A14), time of day (A15), individual three dimensional wind scenarios (A16), previously stored jump partners (A17), malfunctions such as line twists (A18), and canopy opening location. These opening locations are specified relative to he ideal for a particular wind scenario in parachutist terms, i.e. long or short (A18), left or right (A20), direction (A21), initial altitude (A22) followed by a chance to change any individual choices (A23).
Referring now to FIGS. 11A and 11B, a functional block diagram is shown illustrating options available in the system of the invention during and after the jump has been made.
Before a run actually starts, an overhead map view may be displayed and the run can be started with a final initial choice. The program continually checks via collision logic (A25) to see if the jumper has contacted another object including the ground. It also checks to see if the instructor has pushed a key (escape key) to halt the run (A26) or change the various display options such as a smoke cloud or wind sock (A27), alternative jump spot (A28), or wind line (A29). If a second escape key is pushed, the run ends (A30). For other keys, the appropriate display change occurs, and the run continues. Throughout the run, the program monitors control activity and parachute motion and displays an indication to the jumper of excessive control activity. At the end of a run occasioned by a collision or touchdown, the point of view rotates to directly down, with boot outlines displayed at the center of the screen (A31), and the point of view pulls up to show landing location. If the jumper has succeeded in landing, a score screen appears (A32) showing the automatic scoring during a run and a score based on preset limit values for velocities at touchdown, as well as landing accuracy.
At the end of the run, the instructor can choose to store the run for playback (A33), for display as jumped, for use as a jump partner, or a run can be loaded from storage. The Jump Evaluation Menu (A37) provides inputs to "Enter Attitude" (A35) and "On Ground or at Altitude" (A36). The performance during the run can be displayed from the parachutist's perspective, from overhead in a map like view, from a location determined by a joystick, or in a variety or different map views which can be printed. The instructor can then choose to start a new run or exit the program.
In order to provide the appearance of realistic three-dimensional trees in the scenarios, while maintaining the low polygon count required for rendering efficiency and real-time performance, simplified geometric structures with applied foliage images are used. This approach is commonly used in three-dimensional graphics projects, with the structures in the form of two vertically oriented rectangular models intersecting at right angles. The novel aspect of the models used in this device is that they are comprised of both vertical and horizontal cross-sectional images applied to the appropriate planes. This approach provides a realistic view of the trees from above, as a descending parachutist would actually see them. In most other devices, such models are viewed only from eye level; if other view points are required, a full geometry is needed. The cross-sectional approach provides a realistic model from all view points while avoiding the high polygon count models required by full geometry trees. Additional 3-dimension appearance is provided by associating a bit map shadow with the object. The separate shadow object is not checked by the collision logic.
A problem inherent in may realistic 3-dimensional graphics models is that of texture scale. Since most applications view scenarios from a limited range of distance, the common answer to the problem of ground texture is to select a compromise value; that is a texture scaled to be seen from the most frequently used view point. Naturally, if the view point moves closer to the model, the texture will appear too large and may even dissolve into its component pixels. In the opposite case, if the viewpoint moves farther from the object, fine textures will not be visible and may blur into a general color or was of colors.
For the parachute simulation, a single compromise would not serve. As the user initially views the scenario from a height of up to several thousand feet, the ground texture must be scaled up for correct appearance from these heights. However, during the duration of a run, the parachutist falls towards the ground, with the ground texture becoming relatively larger and larger in appearance. For a ground surface to have the correct appearance at the beginning and throughout most of the run, the texture had to be scaled to a point where, when the user actually landed at the end of the run, the ground surface appeared to be a multicolored patchwork quilt of pixels.
To avoid this problem, the ground was modeled in two layers. The overall ground model was covered by a texture map giving the appropriate appearance from the beginning of the run. A second layer was created to cover the drop zone. This layer was textured with a fine scale alpha channeled surface grass map (for the forest and urban scenarios) or water map(for the ocean scenario). As they include alpha channels, these finely textured surfaces are partially transparent, permitting the underlying surface color to show through. At the end of a simulation run, on approach landing, the user is suddenly able to distinguish the landing surface itself as grass or other appropriate material. This provides a valuable microtexture ground rush visual landing cue.
While the invention has been described and illustrated in detail it is to be understand that this is intended by way of illustration and example only, the scope of the invention being limited only by the terms of the following claims.
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The experience of parachute flight is simulated including parachute release and malfunctions. The parachutist trainee is suspended in a harness and a control line provided for the parachutist to operate. The parachutist's actions are sensed by an action sensor actuated by the control line. Force and position sensors sense position and force factors effected by the parachutist. The parachutist's head motion can be tracked by a head mounted sensor. The outputs of the sensors are converted to digital signals which are fed to a computer. The computer is programmed with a mathematical and logical model of parachute dynamics and environmental factors. The computational results are displayed to the parachutist on a monitor or on a head mounted display, the scene viewed containing a variety of three dimensional representations of objects on the ground such as buildings vegetation roads, etc. The responses of the parachutist and computed motions of the parachutist are scored continually for activity level and accuracy. The run ends when collision logic detects intersection with other simulated objects, e.g. when the parachutist touches ground in the simulation.
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TECHNICAL FIELD
[0001] The present invention assigns to a device for quantitative and qualitative determination of chemical substances in a liquid flow from a micro-dialysis probe, filter unit, fermenter, cell suspension, chemical reactor, human being, tissue or animal.
[0002] The device can also act as a component in equipment for automatic regulation and control of chemical and/or biological processes in fermenters, cell suspensions and chemical reactors.
TECHNICAL BACKGROUND
[0003] The annual world market for liquid chromatography has, from the beginning of the 1960s until today, grown extensively. The market leaders in this area are companies like Pharmacia & Upjohn AB, Applied Biosystems Inc, Bioanalytical Systems, Hitatchi Instruments and Waters Corporation.
[0004] In parallel with this development, tools such as micro-dialysis probes, have been produced for in vivo monitoring of patients and animals. Companies that are acting in this area include CMA Microdialys AB (Sweden) and SpectRx Inc (USA).
[0005] A third area involving monitoring and control of chemical processes and fermenters is under development. Companies that are active in this area are e.g. Applikon (NL), YSI Inc (USA) and Trace Biotech Ag (Germany). The latter company has developed a micro-dialysis like device for sampling from a fermentor under sterile conditions.
[0006] The common point in the mentioned three areas is that they are all dependent on detection systems, which preferentially are of the type: a flow-through detector. Using different types of flow-through detectors several important chemical substances can be identified and quantified in different types of measuring matrices, exemplified, but not limited to fermentation broths, blood, cerebrospinal fluid, urine etc.
[0007] Calibration of a flow-through cell is necessary to obtain accurate measuring results in qualitative and quantitative determination of chemical substances in liquid flows from micro-dialysis probes, filter units, fermenters, cell suspensions, chemical reacters, human beings, tissues and animals. The need for calibration originates from the effects on the measuring results from the flow-through cell emanating from either contamination caused by components in the matrix present in the mentioned liquid flow, and/or time dependent fluctuations of the composition of the liquid flow matrix. The latter fluctuations in the liquid flow matrix composition can arise as a result of chemical or biological processes in chemical reactors, fermenters, cell suspensions, and organisms like cells, tissue, human being, animal, plant, micro-organism or funghus.
[0008] It is already commonly known that calibration of chemical measuring equipment can be performed with a generally accepted procedure that goes by the name of the standard addition method, i.e. a known amount of the substance that is going to be analysed is added to the sample solution to be analysed. The procedure is based on that a first measurement is performed on the pure sample without any addition, followed by one (or more) new measurement(-s) on the sample now containing an addition of a known standard. The amount of the mentioned substance can then be accurately calculated with mathematical methods.
[0009] The problem with this method is that it is cumbersome, time-consuming and demands substantial manual work.
[0010] Since 1995 a new type of biosensor technology, SIRE Biosensor, has been developed, which is based on the injection of recognition elements [SE 510 733 (1999), U.S. Pat. No. 6,214,206 (2001) & U.S. Pat. No. 6,706,160 (2004)]. This technology has solved many technological problems usually related to measuring of chemical substances. The present invention can preferentially be integrated with the mentioned technology since it can use injectable enzymes as reagents, but with the difference that it is based on a new technological construction, which solves problems, that arise in qualitative and quantitative measurements of chemical substances in liquid flows, in a new and unexpected way.
[0011] So far few technical solutions have been presented that in a powerful and automatisisable way solve the problems which arise in calibration of flow-through detectors.
[0012] The present invention solves the problems with calibration in a completely new way. The most important advantages with the present invention is in particular the facts that low molecular substances can be determined qualitatively and quantitatively with the reliably calibrated flow-through detector and that this detector can be joined in direct connection with a sample outlet.
SUMMARY OF THE INVENTION
[0013] The present invention is a device, characterised by that it consists of a membrane that separates two flow-through chambers, where the first of the flow-through chambers contains a detector and an inlet and an outlet for a liquid flow, and the second flow-through chamber has a minimum of two inlets for liquid flows and a minimum of one outlet for a liquid flow.
[0014] The invention also refers to a method where a device according to the invention is used for calibration through standard addition, alternatively through usual calibration without the procedure for standard addition.
[0015] The invention also refers to a method where a device according to the invention is espescially used for quantitative and qualitative detection of substances in liquid flows in liquid chromatography (e.g. capillary LC, HPLC, FPLC, Affinity Chromatography and Gel Filtration), and for standard addition calibrated detection of low molecular substances exemplified but not limited to glucose, lactate, sucrose, ethanol, methanol, ascorbic acid, lactose, maltose, malic acid, citric acid or acetic acid in a liquid flow from a micro-dialysis probe, filter unit, fermenter, cell suspension, chemical reactor, human being, tissue or animal.
SHORT DESCRIPTION OF DRAWINGS
[0016] FIG. 1 shows a principal schedule of the device according to the present invention. A liquid flow containing the substance to be detected is guided through inlet A to flow-through chamber B. Through inlet C a liquid flow that contains only buffer solution, alternatively buffer solution with a known amount of the substance to be determined. Both liquid flows are mixed in flow-through chamber B. The substance to be detected diffuses through the membrane F into flow-through chamber G where it can react with reagents, e.g. enzymes, that have been introduced to this chamber through inlet J. The substance or substrate/products that are consumed/produced in the enzymatic reaction generates a measuring signal when in contact with the detector H. The liquid in flow-through chamber G is let out through outlet K. The liquid in flow-through chamber B is let out through outlet E. Inlet J and outlet K in flow-through chamber G can be reversed so that flows run opposite to each other.
DETAILED DESCRIPTION OF THE INVENTION
[0017] According to one aspect of the invention, the device is characterised by that one and each of the flow-through chambers have a chamber volume interval of 0.1-5000 μl.
[0018] According to another aspect, the device is characterised by that the detector consists of an amperometric three-electrode system containing a working electrode made of Platinum, a reference electrode made of Silver and a counter electrode made of Platinum or Silver.
[0019] According to an additional aspect, the device according to the invention characterised by that the working electrode has a potential that lies +200 to +1000 mV above a Silver or Silver/Silver Chloride reference electrode potential.
[0020] According to an additional aspect of the invention, the received individual measuring signals from buffer, sample, sample added through standard addition, alternatively only standard, are used to calculate background compensated and calibrated quantitative and qualitative measuring results as defined by the SIRE Biosensor concept.
[0021] According to an additional aspect of the invention, the device is characterised by that it is equipped with a mixing unit D ( FIG. 1 ) consisting of a magnetic rod or paddles, which are operated internally or externally by a mechanical motion or a rotating magnetic field.
[0022] According to an additional aspect of the invention, the device is characterised by that it is equipped with a heat-generating or cooling element for thermo control of the device to keep a constant temperature in the interval 5 to 80 degrees Celsius. This will among other things secure that fluctuations in the temperature of the surrounding area of the device will not affect the diffusion over the membrane F ( FIG. 1 ) which in turn will affect the measuring signal.
[0023] According to an additional aspect of the invention, the device is characterised by that it is equipped with temperature sensor for mathematical compensation of the measuring signal by software at temperature fluctuations.
[0024] According to one aspect the measuring principle is based on that the detector H ( FIG. 1 ) is a SIRE Biosensor mentioned earlier in this patent application.
[0025] FIG. 1 shows a principal schedule over the device. A liquid flow, e.g. 0.1 M phosphate buffer pH 7.4, containing the substance to be detected is guided through inlet A to flow-through chamber B. Through inlet C a liquid flow containing only buffer solution, alternatively a buffer solution containing a known amount of substance to be determined, e.g. 1 mM Glucose or Lactate. Both liquid flows are mixed in flow-through chamber B. The substance, e.g. Glucose, to be detected diffuses through the membrane F, e.g. a dialysis membrane (MWCO=3 kDa) made of cellulose acetate, into flow-through chamber G, where it can react with enzymes such as glucose oxidase or lactate oxidase, that has been introduced in liquid flows, e.g. 0.1 M phosphate buffer pH 7.4, through inlet J. The substance or the substrate/products that are consumed/produced by the enzymatic reaction generates an electrochemical or amperometric or optical measuring signal when in contact with the detector H. The liquid in flow-through chamber G is let out through outlet K. The liquid in flow-through chamber B is let out through outlet E. Inlet J and outlet K in flow-through chamber G can be reversed so that an opposite flow is received.
[0026] The liquid flows through the flow-through chambers can e.g. be established by the use of pumps alternatively by self-acting flow. Switching between different liquid flows containing a known substance alternatively enzymatic reagents is e.g. performed with external valves. Mixing of the different liquid flows that is introduced in flow-through chamber B can be done passively by diffusion, alternatively by laminar/turbulent flow, alternatively by stirring with a magnetic rod or a paddle.
[0027] By using more than two inlets to flow-through cell B, more than two different liquid flows be introduced in the mentioned flow-through cell independent of each other. This means that the number of external valves can be reduced and that different substances and different concentrations of the substance to be determined can be introduced into flow-through chamber B. Consequently, more than one substance can be analysed. In addition, series (2-200) of measuring values for standard addition graphs are received resulting in more accurate measuring results.
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A device and method are provided for the reliable calibration of detector units for the detection of low-molecular substances in a liquid flow.
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CROSS-REFERENCE TO CO-PENDING APPLICATIONS
[0001] The present application is related to and claims priority to U.S. Provisional Application Serial No. 60/331,995, filed Nov. 23, 2001. The contents of that application are incorporated herein by reference.
[0002] The present invention was made in part with U.S. Government support under grant number ROI AR42739 from the National Institute of Health. The U.S. Government may have certain rights to this invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to a method and system for the computerized diagnosis of bone disease on radiographic images.
[0005] The present invention also generally relates to computerized techniques for automated analysis of digital images, for example, as disclosed in one or more of U.S. Pat. Nos. 4,839,807; 4,841,555; 4,851,984; 4,875,165; 4,907,156; 4,918,534; 5,072,384; 5,133,020; 5,150,292; 5,224,177; 5,289,374; 5,319,549; 5,343,390; 5,359,513; 5,452,367; 5,463,548; 5,491,627; 5,537,485; 5,598,481; 5,622,171; 5,638,458; 5,657,362; 5,666,434; 5,673,332; 5,668,888; 5,732,697; 5,740,268; 5,790,690; 5,832,103; 5,873,824; 5,881,124; 5,931,780; 5,974,165; 5,982,915; 5,984,870; 5,987,345; 6,011,862; 6,058,322; 6,067,373; 6,075,878; 6,078,680; 6,088,473; 6,112,112; 6,138,045; 6,141,437; 6,185,320; 6,205,348; 6,240,201; 6,282,305; 6,282,307; 6,317,617; 6,335,980, 6,363,163; 6,442,287, 6,466,689; 6,470,092; 6,483,934 as well as U.S. patent application Ser. Nos. 09/692,218; 09/759,333; 09/760,854; 09/773,636; 09/816,217; 09/830,562; 09/818,831; 09/860,574; 10/270,674; 10,292,625; No. 60/395,305; and co-pending application Ser. Nos. 09/990,311 and 09/990,310; and PCT patent applications PCT/US00/41299; PCT/US01/00680; PCT/US01/01478 and PCT/US01/01479, all of which are incorporated herein by reference.
[0006] The present invention includes use of various technologies referenced and described in the above-noted U.S. patents and applications, as well as described in the references identified in the following LIST OF REFERENCES by the author(s) and year of publication and cross referenced throughout the specification by reference to the respective number, in parenthesis, of the reference:
LIST OF REFERENCES
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[0019] 13. Ross, P. D., Davis, J. W., Vogel J. M. and Wasnich R. D. A critical review of bone mass and the risk of fracture in osteoporosis. Calcif. Tissue Int. 46:149-161; 1990.
[0020] 14. Sartoris, D. J. and Resnick, D. Current and innovation methods for noninvasive bone densitometry. Radiologic Clinics of North America 28:257-278; 1990.
[0021] 15. Seeman, E. Editorial: Growth in bone mass and size are racial and gender differences in bone mineral density more apparent than real? J. Clin. Endocrinol. Metab. 83:1414-1419; 1998.
[0022] 16. Sieranen, H., Kannus, P., Oja, P. and Vuori, I. Dual-energy X-ray absorptiometry is also an accurate and precise method to measure the dimensions of human long bones. Calcif. Tissue Int. 54: 101-105; 1994.
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[0025] 19. S. M. Bentzen, I. Hvid and J. Jorgensen, “Mechanical strength of tibial trabecular bone evaluation by x-ray computed tomography,” J. Biomech. 20, 743-752 (1987).
[0026] 20. G. H. Brandenburger, “Clinical determination of bone quality: is ultrasound an answer,” Calcif. Tissue Int. 53, S151-S156 (1990).
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[0028] 22. D. A. Chakkalakl, L. Lippiello, R. F. Wilson, R. Shindell and J. F. Connolly, “Mineral and matrix contributions to rigidity in fracture healing,” J. Biomech. 23, 425-434 (1990).
[0029] 23. S. C. Cowin, W. C. Van Buskirk and R. B. Ashman, “Properties of bone,” In Handbook of Bioengineering: edited by R. Skalak and S. Chien, 2.1-2.28, (McGraw-Hill, NY, 1987).
[0030] 24. P. 1. Croucher, N. J. Garrahan and J. E. Compston, “Assessment of cancellous bone structure: comparison of strut analysis, trabecular bone pattern factor, and marrow space star volume,” J. Bone Miner. Res. 11, 955-961 (1996).
[0031] 25. E. P. Durand and P. Ruegsegger, “High-contrast resolution of CT images for bone structure analysis,” Med. Phys. 19, 569-573 (1992).
[0032] 26. J. C. Elliott, P. Anderson, R. Boakes and S. D. Dover, “Scanning X-ray microradiography and microtomography of calcified tissue,” In Calcified Tissue: edited by D. W. L. Hukins, (CRC Press, inc. Boca Raton, Fla., 1989).
[0033] 27. K. G. Faulkner, C. Gluer, S. Majumdar, P. Lang, K. Engelke and H. K. Genant, “Noninvasive measurements of bone mass, structure, and strength: current methods and experimental techniques,” AJR 157, 1229-1237 (1991).
[0034] 28. L. A. Feldkamp, S. A. Goldstein, A. M. Parfitt, G. Jesion, and M. Kleerekoper, “The direct examination of three-dimensional bone architecture in vitro by computed tomography,” J. Bone Miner. Res. 4, 3-11 (1989).
[0035] 29. S. A. Goldstein, “The mechanical properties of trabecular bone: dependence on anatomical location and function,” J. Biomech. 20, 1055-1061 (1987).
[0036] 30. R. W. Goulet, S. A. Goldstein, M. J. Ciarelli, J. L. Kuhn, M. B. Brown and L. A. Feldkamp, “The relationship between the structural and orthogonal compressive properties of trabecular bone,” J. Biomech. 27, 375-389 (1994).
[0037] 31. I. Hvid, S. M. Bentzen, F. Linde, L. Mosekilde and B. Pongsoipetch, “X-ray quantitative computed tomography: the relations to physical properties of proximal tibial trabecular bone specimens,” J. Biomech. 22, 837-844 (1989).
[0038] 32. C. Jiang, R. E. Pitt, J. E. A. Bertram, and D. J. Aneshansley, “Fractal-based image texture analysis of trabecular bone architecture,” Medical & Biological Engineering & Computing, Submitted (1998a).
[0039] 33. C. Jiang, R. E. Pitt, J. E. A. Bertram, and D. J. Aneshansley, “Fractal characterization of trabecular bone structure and its relation to mechanical properties,” J. Biomech., Submitted (1998b).
[0040] 34. S. Katsuragawa, K. Doi. and H. MacMahon, Image feature analysis and computer-aided diagnosis in digital radiograph: detection and characterization of interstitial lung disease in digital chest radiographs, Medical Physics 15:311-319 (1988).
[0041] 35. T. M. Keaveny, E. F. Wachtel, C. M. Ford and W. C. Hayes, “Differences between the tensile and compressive strengths of bovine tibial trabecular bone depend on modulus,” J. Biomech. 27, 1137-1146 (1994).
[0042] 36. S. Majumder, R. S. Weinstein and R. R. Prasad, “Application of fractal geometry techniques to the study of trabecular bone,” Med. Phys. 20, 1611-1619 (1993).
[0043] 37. S. Majumder, M. Kothari, P. Augat, D. C. Newitt, T. M. Link, J. C. Lin, T. Lang, Y. Lu and H. K. Genant, “High-resolution magnetic resonance imaging: three-dimensional trabecular bone architecture and biomechanical properties,” Bone 55, 445-454 (1998).
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[0045] 39. P. Maragos, “Fractal signal analysis using mathematical morphology,” Advances in Electronics and Electron Physics 88, 199-246 (1994).
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[0054] 2. Discussion of the Background
[0055] Although there are many factors that affect bone quality, two primary determinants of bone mechanical properties are bone mineral density (BMD) and bone structure. Among the density and structural features extracted from bone using various techniques, researchers agree that BMD is the single most important predictor of bone strength as well as disease-conditions, such as osteoporosis. Studies have shown a correlation between BMD and bone strength (see references 1, 3, and 8). For this purpose, a range of techniques have been developed to measure BMD and to evaluate fracture risk, to diagnose osteoporosis, to monitor therapy of osteoporosis, and to predict bone strength (see references 3, 6 and 13).
[0056] The standard technique for noninvasive evaluation of bone mineral status is bone densitometry. Among various techniques for bone densitometric measurement, dual energy X-ray absorptiometry (DXA) is relatively inexpensive, low in radiation dose (<5 FSv effective dose equivalent), and of high accuracy (about 1%) and precision (about 1%) (see references 9, 14). DXA has gain widespread clinical acceptance for the routine diagnosis and monitoring of osteoporosis. In addition, DXA can be directly used to measure whole bone geometric features (see references 5, 7, 9, and 16). The BMD measurement from DXA, however, is only moderately correlated to bone mechanical properties, and has limited power in separating the patients with and without osteoporosis-associated fractures (see reference 2). DXA is an integral measure of cortical and trabecular bone mineral content along the X-ray path for a given projected area and only measures bone mass, not bone structure. As a consequence, DXA measurements are bone-size dependent and yield only bone mineral density per unit area (g/cm 2 ) instead of true density, i.e., volumetric bone mineral density (g/cm 3 ). Therefore, if the BMD measurements of patients with different bone sizes are compared, the results can be misleading.
[0057] Although the effect of bone size on area BMD using DXA is apparent (see references 4 and 15), only a few studies (see references 3, 10, and 12) have been performed to account for such a bias. To compensate for the effect of bone size for vertebral bodies, researchers have developed an analysis method and suggested a new parameter, bone mineral apparent density (BMAD), as a measure of volumetric bone mineral density (see reference 4).
[0058] In clinical application, because of bone size variation, it is impossible to measure true volumetric BMD with DXA. Nevertheless, for the purpose of comparison of individuals with different bone sizes, it is possible to normalize the area-based BMD with a geometric dimension that is proportional to bone thickness in a noninvasive manner.
[0059] Also, one of the functions of bone is to resist mechanical failure such as fracture and permanent deformation. Therefore, biomechanical properties are fundamental measures of bone quality. The biomechanical properties of trabecular bone are primarily determined by its intrinsic material properties and the macroscopic structural properties (see references 8, 20, 23, and 22). Extensive efforts have been made to evaluate bone mechanical properties by studying bone mineral density (BMD) and mineral distribution.
[0060] Since bone structural rigidity is derived primarily from its mineral content (see reference 26), most evaluation methods have been developed to measure bone mass (mineral content or density) and to relate these measures to bone mechanical properties (see references 3, 8, 19, 31, and 35). Results from in vivo and in vitro studies suggest that BMD measurements are only moderately correlated to bone strength (see reference 4). However, studies have shown changes in bone mechanical properties and structure that are independent of bone mineral density (see references 27 and 29). Moreover, because density is an average measurement of bone mineral content within bone specimens, it does not include information about bone architecture or structure.
[0061] Various methods have been developed for in vitro study of the two- or three-dimensional architecture of trabecular bones using histological and stereological analyses (see references 28, 29, 30, and 43). These studies have shown that, by combining structural features with bone density, 72 to 94 percent of the variability in mechanically measured Young's moduli could be explained. However, these measurements are invasive.
[0062] For the noninvasive examination of trabecular bone structure, investigators have developed high-resolution computed tomography (CT) and magnetic resonance imaging (MRI) (see references 25, 28, and 36). However, due to cost and/or other technical difficulties, these techniques are currently not in routine clinical use. The potential use of X-ray radiographs to characterize trabecular bone structure has also been studied. Although the appearance of trabecular structure on a radiograph is very complex, studies have suggested that fractal analysis may yield a sensitive descriptor to characterize trabecular structure from x-ray radiographs both in in vitro studies (see references 18, 39 and 44) and in an in vivo study (see reference 34).
[0063] Different methods, however, exist with which to compute fractal dimension. Minkowski dimension, a class of fractal dimension that is identical to Hausdroff dimension (see reference 38), is particularly suitable for analyzing the complex texture of digital images because it can be formally defined through mathematical morphology, and easily computed using morphological operations (see references 39 and 42). The Minkowski dimension computed from an image, regardless of texture orientation, gives a global dimension that characterizes the overall roughness of image texture. Similarly, the Minkowski dimensions computed from different orientations yield directional dimensions that can be used to characterize the textural anisotropy of an image (see reference 33).
[0064] Studies have also been performed demonstrating the important contributions of normalized BMD, structural features, and age to bone mechanical properties, i.e., bone strength (see references 45, 46, and 47). In addition, the limitation of fractal-based analyses was shown to be overcome with the use of an artificial neural network (ANN) to extract fractal information.
SUMMARY OF THE INVENTION
[0065] Accordingly, an object of the present invention is to provide a method, system, and computer program product for the analysis of bone mass, strength, and structure.
[0066] Another object of this invention is to perform texture analysis using the trabecular mass and bone pattern from digital radiographic images, obtained with a bone densitometer, for the assessment of bone strength and/or osteoporosis and as an indicator or predictor of bone disease.
[0067] Yet another object of this invention is to perform analysis of regions within the oscalcsis analysis of the trabecular mass and bone pattern for the assessment of bone strength and/or steoporosis and for an indicator or predictor of bone disease.
[0068] These and other objects are achieved by way of a method, system, and computer program product for analyzing a medical image to determine a measure of bone strength, comprising: (1) identifying plural regions of interest (ROIs) in the medical image; (2) calculating at least one texture feature value for each ROI; (3) averaging the at least one texture feature value calculated for each ROI to obtain at least one average texture feature value; and (4) determining the measure of bone strength based on the at least one average texture feature value.
[0069] In addition, according to another aspect of the present invention, there is provided a novel method, system, and computer program product for analyzing a medical image to determine a measure of bone strength, comprising: (1) identifying plural regions of interest (ROIs) in the medical image; (2) transforming image data in each of said ROIs into respective frequency domain image data; (3) averaging the respective frequency domain image data to obtain average image data; (4) calculating at least one texture feature value from the average image data; and (5) determining the measure of bone strength based on the at least one texture feature value.
[0070] In addition, according to still another aspect of the present invention, there is provided a novel method, system, and computer program product for analyzing plural medical images to determine a measure of bone strength, comprising: (1) identifying a region of interest (ROI) having a corresponding center pixel in each medical image; (2) transforming image data in the ROI of each medical image into respective frequency domain image data; (3) averaging the respective frequency domain image data to obtain an average image; (4) calculating at least one texture feature value from the average image; and (5) determining the measure of bone strength based on the at least one texture feature value.
[0071] In addition, according to still another aspect of the present invention, there is provided a novel method, system, and computer program product for analyzing a medical image to determine a measure of bone strength, comprising: (1) identifying plural regions of interest (ROIs) in the medical image, each ROI having a corresponding center pixel; (2) transforming image data in each of said ROIs into respective frequency domain image data; (3) calculating at least one texture feature value for each ROI using the respective frequency domain image data; and (4) determining the measure of bone strength based on the at least one texture feature value.
[0072] In addition, according to still another aspect of the present invention, there is provided a novel method, system, and computer program product for analyzing plural medical images to form at least one texture feature image, comprising: (1) identifying a region of interest (ROI) having a corresponding center pixel in each medical image; (2) calculating at least one texture feature value for the ROI in each medical image; (3) averaging the at least one texture feature value of each medical image in the plural medical images; (4) repeating the identifying, calculating, and averaging steps for a plurality of ROIs having a corresponding plurality of center pixels; (5) associating the at least one feature value calculated in each calculating step with a center pixel in the corresponding plurality of center pixels to form the at least one texture feature image.
[0073] In addition, an aspect of the present invention is the use of area-based BMD and volumetric BMD as predictors of bone mechanical properties, and a procedure for non-invasively normalizing BMD values for use in clinical applications.
[0074] A further aspect of the present invention is the use of an estimate of risk of fracture, a reduction of noise in skeletal imaging of the trabecular pattern, and a visualization of texture feature images in assessing bone strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0076] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0077] [0077]FIG. 1 a is a flowchart illustrating a method of analysis of bone structure from plural images according to the present invention;
[0078] [0078]FIG. 1 b is a flowchart illustrating a method for analysis of bone structure from a single image according to the present invention;
[0079] [0079]FIG. 1 c is a flowchart illustrating a second method for analysis of bone structure from a single image according to the present invention;
[0080] [0080]FIG. 1 d is a flowchart illustrating a third method for analysis of bone structure from a single image according to the present invention;
[0081] [0081]FIG. 2 is an image illustrating a high resolution digital radiographic heel image (0.2 mm pixel size) from a commercial portable peripheral bone densitometer;
[0082] [0082]FIG. 3 is a graph illustrating a plot of the relationship between the first moment texture feature for the individual image and for the measure obtained from the average of five ROIs in the spatial frequency domain for cases in a first database (Database 1);
[0083] [0083]FIG. 4 is a graph illustrating a plot of the relationship between the first moment texture feature for the individual image and for the measure obtained from the average of two ROIs in the spatial frequency domain for cases in a second database (Database 2);
[0084] [0084]FIG. 5 is an image illustrating a first moment feature image for a heel for a case with a spine fracture;
[0085] [0085]FIG. 6 is an image illustrating a first moment feature image for the heel for a case without a spine fracture;
[0086] [0086]FIG. 7 is a block diagram illustrating a system for the analysis of bone mass and/or bone structure according to the present invention;
[0087] [0087]FIG. 8 is a flowchart illustrating a method for the calculation of a texture feature image using multiple image exposures;
[0088] [0088]FIG. 9 is a flowchart illustrating a second method for the calculation of a texture feature image using multiple image exposures; and
[0089] [0089]FIG. 10 is a flowchart illustrating a method for the calculation of a texture feature image using a single image exposure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0090] Referring now to the drawings, and more particularly to FIG. 1 a thereof, a method for the analysis of bone is shown. In this example, the characteristics of the bone trabecular pattern using computer analysis of image data from digital images of bony parts of the body, for example, the heel are extracted. Although the heel is used as an example, it should be appreciated that alternate bony parts of the body may be used. Further, for the purposes of this description we shall define image to be a representation of a physical scene, in which the image has been generated by some imaging technology. Examples of imaging technology include television, CCD cameras, X-ray, sonar or ultrasound imaging devices, CT or MRI devices, etc. The initial medium on which an image is recorded could be an electronic solid-state device, a photographic film, or some other device such as a photostimulable phosphor. The recorded image may be then converted into digital form by a combination of electronic means (used for example with images from CCD signal) or mechanical/optical means (used for example with digitizing a photographic film or data from photostimulable phosphor). An image may have any number of dimensions including one (e.g. acoustic signals), two (e.g. X-ray radiological images) or more (e.g. nuclear magnetic resonance images).
[0091] The present invention is preferably computer implemented and can be configured to accept image data either from an image acquisition device directly from an image digitizer or from an image storage device. The image storage device may be local, e.g., associated with an image acquisition device or image digitizer, or may be remote so that upon being accessed for processing according to the present invention, the image data is transmitted via a network, for example a Picture Archiving Communications System (PACS) or other network.
[0092] With a continued reference to FIG. 1 a , images, digital bone images are obtained in parallel steps 101 a , 101 b , 101 c , and 101 d . An exemplary bone image is a digital radiograph of the heel, for example.
[0093] Next, in parallel steps 102 a , 102 b , 102 c , and 102 d , regions of interest (ROIs) are obtained in each respective digital bone image obtained in steps 101 a , 101 b , 101 c , and 101 d . The image data corresponding to the ROIs may be stored in memory. Note that bone mineral densitometry (not shown) may be performed on the individual images of the bone and also stored in memory (not shown).
[0094] Next, in parallel steps 103 a , 103 b , 103 c , and 103 d , a two-dimensional discrete Fourier transform of the image data in the respective ROIs is calculated.
[0095] In step 104 , the Fourier-transformed ROI image data is averaged, thus reducing noise.
[0096] Next, in step 105 , texture feature calculations are performed on the averaged ROI data to produce characteristics of the bone texture. Various individual textures measures are calculated using texture schemes, e.g., texture measures requiring Fourier analysis. In addition, the Minkowski dimension and other appropriate texture measures can also be calculated.
[0097] Next, in step 106 , bone texture feature values and feature-related data (e.g., bone mass) are merged. Other feature related data that may be merged with bone texture include bone geometry, bone structure, and clinical data, such as the age of the subject. Merging is performed by classifiers, such as, but not limited to, a linear discriminant and/or an artificial neural network to yield an estimate output of a numerical value related to bone strength, indicating the likelihood of risk of future fracture.
[0098] [0098]FIG. 1 b illustrates a variation of the method of FIG. 1 a in which the use of ROIs from multiple exposures is replaced with different, e.g., neighboring ROIs from a single exposure. In step 101 , a digital bone image is obtained. Next, in parallel steps 102 e , 102 f , 102 g , and 102 h , regions of interest (ROIs) are obtained in the digital bone image obtained in step 101 . Again, the image data corresponding to the ROIs may be stored in memory. The ROIs are predetermined areas spaced apart from each other by a distance. For example, the ROIs may be spaced apart a distance of about two widths of a ROI. The remaining steps 103 a , 103 b , 103 c , 103 d , 104 , 105 , and 106 are the same as the corresponding steps described above with reference to FIG. 1 a.
[0099] [0099]FIG. 1 c illustrates a modification of the method of FIG. 1 b in which the step of averaging the frequency domain data (step 104 ) is omitted. The remaining steps of FIG. 1 c are the same as the steps of FIG. 1 b. In step 101 , a digital bone image is obtained. Next, in parallel steps 102 e , 102 f , 102 g , and 102 h , regions of interest (ROIs) are obtained in the digital bone image obtained in step 101 . Again, the image data corresponding to the ROIs may be stored in memory. The ROIs are predetermined areas spaced apart from each other by a distance. For example, the ROIs may be spaced apart a distance of about two widths of a ROI. Next, in parallel steps 103 a , 103 b , 103 c , and 103 d , a two-dimensional discrete Fourier transform of the image data in the respective ROIs is calculated. Next, in step 105 c , texture feature calculations are performed on the Fourier transformed ROI data. Note that the Fourier transformed ROI data is not averaged in this embodiment. Finally, in step 106 , the bone texture feature values computed in step 105 c and feature-related data (e.g., bone mass) are merged. Again, merging is performed by classifiers, such as, but not limited to, a linear discriminant and/or an artificial neural network to yield an estimate output of a numerical value related to bone strength, indicating the likelihood of risk of future fracture.
[0100] [0100]FIG. 1 d illustrates a variation of the method of FIG. 1 b in which neighboring ROIs from a single exposure are used to compute texture feature values. In step 101 , a digital bone image is obtained. Next, in parallel steps 102 e , 102 f , 102 g , and 102 h , regions of interest (ROIs) are obtained in the digital bone image obtained in step 101 . The ROIs are predetermined areas spaced apart from each other by a distance. For example, the ROIs may be spaced apart a distance of about two widths of a ROI. Next, in parallel steps 107 a , 107 b , 107 c , and 107 d , texture feature values are calculated for each set of ROI image data selected in steps 102 e , 102 f , 102 g , and 102 h . Note that a Fourier transform is not applied in the method of FIG. 1 d . Next, in step 105 d , the texture feature values obtained in steps 107 a , 107 b , 107 c , and 107 d are averaged. Finally, in step 106 , bone texture and feature-related data (e.g., bone mass) are merged. Other feature related data that may be merged with bone texture include bone geometry, bone structure, and clinical data, such as the age of the subject. Merging is performed by classifiers, such as, but not limited to, a linear discriminant and/or an artificial neural network to yield an estimate output of a numerical value related to bone strength, indicating the likelihood of risk of future fracture.
[0101] To implement and test the method of the present invention, databases were created for storing the information related to the analysis of bone structure and disease. An exemplary database would contain digital radiographic images obtained, for example, on a commercial portable peripheral bone densitometer for the calcaneus or forearm. In the present study, images of the calcaneus were obtained. The system, comprising a CCD camera with a GdO 2 S screen, produces high- and low-energy images in order to perform dual energy subtraction to calculate BMD (bone mineral density). The images were obtained at an exemplary pixel size of 0.2 mm.
[0102] A first exemplary database, Database 1, was created with data obtained from thirteen individuals for whom the heel was scanned five times. The exemplary individuals included young, normal volunteers as well as seven osteoporotic patients. Another second exemplary database (Database 2) was created for a second group that included forty-one individuals, for which the heel was scanned twice. Further categorization could be made. For example, the second group might be further categorized into two groups, based upon the presence of a vertebral fracture. In the exemplary data, eleven individuals were identified as having a vertebral fracture and 30 individuals were identified as not having a vertebral fracture. This categorization of vertebral fractures may be used in determining bone strength, since individuals with a vertebral fracture are at a greater risk of getting another fracture, as compared to individuals without a vertebral fracture.
[0103] [0103]FIG. 2 illustrates an exemplary high-resolution image of the calcaneus. In the acquisition of the image exposures, the heel is not repositioned between scans. Typically, only a slight shift of the heel occurs between scans. In this study, a 64-pixel by 64-pixel ROI was manually selected with the same center pixels the ROI used in a measurement of, e.g., the BMD by the commercial system.
[0104] The presence of quantum mottle may limit the use of texture features to adequately quantify bone structure. Thus averaging of image data is commonly used to reduce quantum mottle in images. However, in the analysis of bone trabecular, the averaging of two trabecular pattern ROIs could result in image blur due to a slight shift of the heel between scans. In order to reduce the effect of noise of a trabecular pattern, each ROI is first transformed to spatial frequency space, using, for example, a two-dimensional Fourier transform. Next, in one embodiment, the ROIs are averaged in frequency space, which reduces noise. In addition, calculation errors from image blur from misregistration are also reduced because in the frequency domain, the averaging is of the Fourier components at each relevant (spatial) frequency. Note that the lower frequency components of the trabecular pattern will have a smaller round-off error in the averaging process than will the high-frequency noise components. It should be noted that the Fourier transform of the average of two functions may equal the average of the Fourier transforms of each function; however, this equivalency is only in the situation of no misregistration.
[0105] After averaging in the spatial frequency domain, texture features are calculated. For example, one texture feature is the root-mean-square (IRMS):
RMS Variation = ∑ m ∑ n | F m , n | 2 γ log 10 e
[0106] Another texture feature is the first moment of the power spectrum (IFMP):
Fist Moment of the Power Spectrum = ∑ m ∑ n m 2 + n 2 | F m , n | 2 ∑ m ∑ n | F m , n | 2
[0107] Note that F m,n refers to the two-dimensional Fourier transform of the two-dimensional ROI image data, with m and n being spatial wavenumbers. Note that for IRMS, γ is a normalizing factor relating the exposure levels of the imaging system and the gray-level (pixel) values. As will be appreciated by those skilled in the art, this factor is included so that the fluctuation between pixel values in the exposure domain can be related to that in the gray level domain. Finally, it should be appreciated that various other appropriate texture features, such as fractal dimension, may also be calculated.
[0108] After obtaining the texture features, the texture features are combined with the bone mass density (BMD) measurements using, for example, linear discriminant analysis and/or an artificial neural network (ANN). Receiver operator characteristics (ROC) analysis may be used to evaluate the performance of the new texture feature measurements with the area under the ROC curve (A z ) used as a representation of merit in the ability of the feature to distinguish between strong and weak bone.
[0109] [0109]FIG. 3 illustrates that by reducing the high-frequency noise in the image data using averaging, the range of the resulting texture features may be increased. For example, for the first exemplary database described above, the texture feature values of IFMP for the individual images were compared to that for the “frequency-averaged” ROI image data. For the individual ROI analysis, the range of IFMP feature values is from approximately 1.3 to 1.55 cycles/mm, a difference of 0.25 cycles/mm. For the averaged ROI image data, the range of IFMP feature values is approximately 1.05 to 1.4 cycles/mm, a difference of 0.35 cycles/mm.
[0110] In FIG. 4, for the second exemplary database described above, the texture features of IFMP for the individual images is compared to that for the spatial-frequency-averaged ROI image data for the individual images. For the ROI analysis for individual images, the exemplary range of IFMP feature values is from approximately 1.13 to 1.48 cycles/mm, a difference of 0.35 cycles/mm. For the averaged ROI data, the range of IFMP feature values is approximately 0.92 to 1.43 cycles/mm, a difference of 0.51 cycles/mm, a. Therefore, FIGS. 3 and 4 illustrate that the range of IFMP values became larger for the average ROI data, as compared to the ROI analysis of individual images.
[0111] The improvement, i.e., the increased range of IFMP values for the averaged ROI data, results in an enhanced ability to distinguish between “strong” and “weak” bone, as shown in Tables 1 and 2, which provide individual ROI A 2 values and averaged ROI A z values for both individual features and merged features. Tables 1 and 2 indicate that an averaging of the multiple ROIs in the frequency domain reduced the contribution of quantum mottle as well as computer round-off error to the calculation of the texture features. Averaging also increased the range of texture feature values and improved the texture feature values performance in distinguishing between strong and weak bone. Avergaing may be especially necessary in the low-dose setting of screening protocols. It should be appreciated that if multiple exposures are not obtained, multiple ROIs in the spatial frequency domain and from the same exposure may be averaged, as in the method illustrated in FIG. 1 b . The utility of this approach assumes that the trabecular pattern does not vary greatly across a given region of the heel.
[0112] Once the texture feature(s) and/or merged features are obtained, the data may be presented numerically, e.g., in terms of the first moment of the power spectrum, or visually, in terms of a feature image in which the texture feature is calculated at each pixel location in the image. The calculation of the texture features may be done for either multiple images or one image since the ROI may be placed at each pixel location in the image and the texture measure calculated at each location.
[0113] [0113]FIGS. 5 and 6 illustrate examples of IFMP feature images. FIG. 5 illustrates an IFMP feature image 600 for an individual with a spine fracture. The color scale indicates high values of the IFMP near green/blue region 610 . FIG. 6 illustrates an IFMP feature image 700 for an individual without a spine fracture. The color scale indicates low values of the IFMP near the green/yellow/red region 710 . The feature image also indicates a consistency of the trabecular pattern throughout the heel bone. Also illustrated is the result of the use of averaging neighboring ROIs in the spatial frequency domain to reduce the noise effect, since the variation across the image is relatively small.
[0114] [0114]FIG. 7 illustrates a system for implementing the method of the present invention for analysis of the bone trabecular structure. Radiographic images of a bone (or other types of images) may be obtained from an Image Acquisition Device 701 and stored in Image Database 720 . Also, it should be appreciated that the source of data may be any appropriate image acquisition device such as an X-ray machine, CT apparatus, or MRI apparatus, for example. Moreover, the Image Database 720 may be located locally or in a remote location, in which case a data communication network, such as PACS (Picture Archiving Computer System), can be used to access the image data at an appropriate time for processing according to the present invention. The radiographic image(s) may be digitized to produce digitized image(s) and stored in Image Database 720 for subsequent retrieval and processing, as may be desired by a user. However, it should be appreciated that if the radiographic image is obtained with a direct digital imaging device, then there is no need for digitization. Further, it should be appreciated that only a single image might be obtained. Note further that the system of FIG. 7 is typically computer implemented, but conceptually can be implemented by discrete circuits or other appropriate devices.
[0115] Image data from the Image Database 720 is first passed through the ROI Selection Unit 702 , which selects at least one ROI from the image data. The Fourier Transform Unit 703 , or another appropriate spatial frequency domain transforming device may receive the image data related to each of the ROIs and transforms the image data into the (spatial) frequency domain. The Spatial-Frequency-Averaging Unit 704 then averages the transformed data. In determining bone structure, the transformed spatial-frequency-averaged data is passed from Spatial-Frequency-Averaging Unit 704 to the Texture Feature Calculation Unit 705 , which calculates texture feature values. Note that, in some embodiments, the ROI image data may be passed directly to the Texture Feature Calculation Unit 705 . The output of the Texture Feature Calculation Unit 705 for multiple ROIs may also be averaged by the Texture Feature Averaging Unit 706 . Other feature related data stored in the Feature Database 730 , which may include measures of bone mass, bone structure, and/or patient data, may be then passed to the Classifier 707 , where it is merged with the texture feature values passed from either the Texture Feature Calculation Unit 705 or the Texture Feature Averaging Unit 706 . The Classifier 707 determines an estimate of bone strength, and thus the likelihood for risk of future fracture. Any and all of the texture features and merged data may be stored in the Image Database 720 . In the Superimposing Unit 708 , the texture feature values and/or merged data are presented as feature images and stored in an appropriate file format or in numerical format. The texture features and/or merged data may be then displayed using a Display Unit 709 , after passing through a digital-to-analog converter (not shown) or any other appropriate processing device.
[0116] [0116]FIG. 8 illustrates the calculation and display of a texture feature image using multiple exposures. In parallel steps 801 a , 801 b , and 801 c N digital bone images are obtained. Initial ROI selection is completed in parallel steps 802 a , 802 b , and 802 c . Selection of neighboring or adjacent ROIs of the heel region (for example) of the images with the center of each ROI corresponding to a pixel location in the ultimate feature image is performed in parallel steps 803 a , 803 b , and 803 c . A feature image may be created from multiple exposures, and therefore noise reduction is performed. In parallel steps 804 a , 804 b , and 804 c , a two-dimensional Fourier transform (or other appropriate transform into the spatial frequency domain) is applied to each ROI selection (e.g., 1 to M) of the N images. Accordingly, the ROI data is transformed to the spatial frequency space.
[0117] In step 805 , the corresponding ROI(i) data from each of the N image data sets is averaged. For example, the ROIs(1) from each of the N images are averaged. In step 806 , at at least one texture feature calculation is performed for the averaged ROI(i) data. In step 807 , bone texture features are merged with bone mass or other appropriate bone-related data. In step 808 , the output from the ROI(i) analysis is related to a pixel location i in each of the feature images. Next, in step 809 , an inquiry is made whether all M ROIs have been processed. If not, steps 805 - 809 are repeated. If the answer to the inquiry is yes, the feature images are displayed in step 810 .
[0118] [0118]FIG. 9 illustrates a second embodiment of the the calculation and display of a texture feature image using multiple exposures. In parallel steps 901 a , 901 b , and 901 c N digital bone images are obtained. Initial ROI selection is completed in parallel steps 902 a , 902 b , and 902 c . Selection of neighboring or adjacent ROIs of the heel region (for example) of the images with the center of each ROI corresponding to a pixel location in the ultimate feature image is performed in parallel steps 903 a , 903 b , and 903 c . A feature image may be created from multiple exposures, and therefore noise reduction is performed. In parallel steps 904 a , 904 b , and 904 c , texture features are calculated for each ROI selection (e.g., 1 to M) of the N images.
[0119] In step 905 , the corresponding ROI(i) data from each of the N image data sets is averaged. For example, the ROIs(1) from each of the N images are averaged. In step 906 , bone texture features are merged with bone mass or other appropriate bone-related data. In step 907 , the output from the ROI(i) analysis is related to a pixel location i in each of the feature images. Next, in step 908 , an inquiry is made whether all M ROIs have been processed. If not, steps 905 - 908 are repeated. If the answer to the inquiry is yes, the feature images are displayed in step 909 .
[0120] [0120]FIG. 10 illustrates calculation and display of the feature images for a single image exposure is shown. In step 1001 , a digital bone exposure image is obtained. Next, initial ROI section of ROI(i) is performed in step 1002 . In step 1003 , neighboring or adjacent ROIs (i+1 to M) are selected. An exemplary exposure image may be a heel region with the center of each ROI corresponding to a pixel location in the ultimate feature image. In step 1004 a two-dimensional Fourier transform (or other appropriate transform into the spatial frequency domain) is applied to each ROI selection.
[0121] In step 1005 , at least one texture feature calculation is performed for ROI(i). In step 1006 , bone texture features are merged with bone mass or other appropriate bone-related data. In step 1007 , the output from the ROI(i) analysis is related to a pixel location i in each of the feature images. Next, in step 1008 , an inquiry is made whether all M ROIs have been processed. If not, steps 1005 - 1008 are repeated. If the answer to the inquiry is yes, the feature images are displayed in step 1009 .
[0122] The source of image data may be any appropriate image acquisition device such as an X-ray machine, CT apparatus, and MRI apparatus. Further, the acquired data may be digitized if not already in digital form. Alternatively, the source of image data being obtained and processed may be a memory storing data produced by an image acquisition device, and the memory may be local or remote, in which case a data communication network, such as PACS (Picture Archiving Computer System), can be used to access the image data for processing according to the present invention.
[0123] This invention conveniently may be implemented using a conventional general purpose computer or micro-processor programmed according to the teachings of the present invention, as will be apparent to those skilled in the computer art. Appropriate software can readily be prepared by programmers of ordinary skill based on the teachings of the present disclosure, as will be apparent to those skilled in the software art.
[0124] As disclosed in cross-referenced U.S. patent application Ser. No. 09/818,831, a computer implements the method of the present invention, wherein the computer housing houses a motherboard which contains a CPU, memory (e.g., DRAM, ROM, EPROM, EEPROM, SRAM, SDRAM, and Flash RAM), and other optional special purpose logic devices (e.g., ASICS) or configurable logic devices (e.g., GAL and reprogrammable FPGA). The computer also includes plural input devices, (e.g., keyboard and mouse), and a display card for controlling a monitor. Additionally, the computer may include a floppy disk drive; other removable media devices (e.g. compact disc, tape, and removable magneto-optical media); and a hard disk or other fixed high density media drives, connected using an appropriate device bus (e.g., a SCSI bus, an Enhanced IDE bus, or an Ultra DMA bus). The computer may also include a compact disc reader, a compact disc reader/writer unit, or a compact disc jukebox, which may be connected to the same device bus or to another device bus.
[0125] As stated above, the system includes at least one computer readable medium. Examples of computer readable media are compact discs, hard disks, floppy disks, tape, magneto-optical disks, PROMs (e.g., EPROM, EEPROM, Flash EPROM), DRAM, SRAM, SDRAM, etc. Stored on any one or on a combination of computer readable media, the present invention includes software for controlling both the hardware of the computer and for enabling the computer to interact with a human user. Such software may include, but is not limited to, device drivers, operating systems and user applications, such as development tools. Computer program products of the present invention include any computer readable medium which stores computer program instructions (e.g., computer code devices) which when executed by a computer causes the computer to perform the method of the present invention. The computer code devices of the present invention can be any interpretable or executable code mechanism, including but not limited to, scripts, interpreters, dynamic link libraries, Java classes, and complete executable programs. Moreover, parts of the processing of the present invention may be distributed (e.g., between (1) multiple CPUs or (2) at least one CPU and at least one configurable logic device) for better performance, reliability, and/or cost. For example, an outline or image may be selected on a first computer and sent to a second computer for remote diagnosis.
[0126] The invention may also be implemented by the preparation of application specific integrated circuits or by interconnecting an appropriate network of conventional component circuits, as will be readily apparent to those skilled in the art.
[0127] Numerous modifications and variations of the present invention are possible in light of the above technique. 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.
TABLE 1 Performance of Features in Distinguishing between Strong & Weak Bone; Database 1 Feature Single ROI (Az) Averaged ROI Data (Az) IRMS 0.624 0.673 IFMP 0.696 0.751
[0128] [0128] TABLE 2 Performance of Features in Distinguishing between Strong & Weak Bone; Database 2; (ROI A z value of BMD = 0.529) Feature Single ROI (Az) Averaged ROI Data (Az) IRMS 0.504 0.570 IFMP 0.506 0.576 IFMP, BMD 0.516 0.576 IRMS, IFMP, 0.531 0.584 BMD
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A method, system, and computer program product for analyzing a medical image to determine a measure of bone strength, comprising identifying plural regions of interest (ROIs) in the medical image; calculating at least one texture feature value for each ROI; averaging the at least one texture feature value calculated for each ROI to obtain at least one average texture feature value; and determining the measure of bone strength based on the at least one average texture feature value using a classifier. Alternatively, the image data in each ROI is first transformed into the frequency domain and averaged to obtain an average image. This process reduces noise and improves the performance of the system. The assessment of bone strength and/or osteoporosis is used as a predictor of risk of fracture.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation-In-Part of patent application Ser. No. 08/079,098 filed Jun. 17, 1993, now abandoned, entitled "ATM ANTI-THEFT DEVICE" by the present inventor.
BACKGROUND OF THE INVENTION
The present invention relates to anti-theft devices for Automated Teller Machines and, more particularly to a device for defacing by blurring or staining, valuable documents such as bank notes or bills in Automated Teller Machines in the event of unauthorized entry or theft.
It has been estimated that in 1991, approximately 8,527 Automated Teller Machines (ATMs) were shipped to companies in the United States while an additional 60,994 were shipped overseas, with the number to surely increase.
With the proliferation of ATMs has come a concurrent rise in the attempted and committed thefts of currency from ATMs since the currency within is not guarded. ATMs are subject to attack by burglars or thefts seeking to extract the currency therefrom. Because ATMs are enclosed in a steel safe-like structure that is extremely difficult to penetrate in a short period of time, therefore the phenomena is occurring of the burglar actually extracting the ATM as a whole. After the burglar has extracted the unit, the ATM is then taken from the premises to another, preferably remote location, where the thief has the time to break into the ATM unit and extract the money contained therein.
Various solutions have been proposed in the prior art to cope with such situations wherein money and/or documents are stored within enclosed containers. One such solution involves the use of pyrotechnical means in which an explosive is utilized to inject a staining liquid into the money/document container. However, such pyrotechnical solutions may be dangerous for persons in the vicinity of the system and, in the case of ATMs which utilize sophisticated machinery and electronics, the use of pyrotechnical means is not desirable in that such may destroy the sophisticated equipment of the ATM and the user.
Another known method are complex mechanical solutions aimed at partially destroying the bank notes by perforating or mutilating the same. These complex systems generally require complicated machinery and a fair amount of power.
Recently, chemical solutions have been devised which generally consist of using discoloring means such as smoke generators for blurring or staining the documents within the container. These products, however, are likely to impair the environment, and in particular the electronic components in the ATM.
Another solution is found in U.S. Pat. No. 5,156,272 issued Oct. 20, 1992 to Bouchard, et al. Essentially Bouchard utilizes a sponge having one or several frangible pockets, phials, ducts or the like. In one embodiment, a piston-like tank pushes an indelible dye into the ducts of the sponge which are then broken or ruptured such that the dye will be delivered to the sponge. The sponge distributes the dye to the documents for blurring the same. Thus, the sponge is an integral part of Bouchard in that the sponge is utilized to distribute the dye over all of the documents within the container. However, such an apparatus as Bouchard utilizing a sponge tends to delay the application of the ink onto the documents as the sponge must first soak up the dye and then when saturated, allow the dye to permeate the container and blur the documents.
It is thus an object of the present invention to overcome the deficiencies in the prior art and provide a safe, quick and effective defacing of documents within an ATM.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for marking banknotes contained within a banknote cassette in an Automated Teller Machine (ATM) upon a breach of security of the ATM. The apparatus comprises a pressurized tank, an indelible liquid ink stored within the pressurized tank, and a manifold operatively associated with the banknote cassette and in communication with the pressurized tank. The manifold provides a distribution path for the ink into the cassette in order for the ink to deface the banknotes upon release of the ink from the tank. Further provided is means for releasing the ink from the pressurized tank upon a breach of security of the ATM such that the ink is delivered under pressure to the banknotes via the manifold to thereby deface the banknotes.
According to one aspect of the present invention, the releasing means comprises an actuator adapted to release the contents of the pressurized tank upon receipt of an actuating signal, and means in communication with the actuator for generating an actuating signal upon a breach of security.
The system is preferably electrical having an electrical input supplied by a normal external power source, typically A.C., or by a battery backup should the normal external power source fail or be interrupted. Various signal generating or input devices may be utilized to trigger the actuator. Control circuitry monitors the various input devices and relays the actuation signal to the tank actuator.
The actuator is generally a pyrotechnic or initiator device and the means for generating an actuating signal may be a mercury switch array, a photoelectric eye, a pendulum tilt switch, a contact or pressure switch, or a gravity ball tilt mechanism. The mercury switch array generates the actuating signal when the ATM is moved in any plane from horizontal. The photoelectric eye provides the actuating signal when a photobeam is interrupted as the entrant crosses the beam. The pendulum tilt also provides a signal upon tilting the ATM from the horizontal plane. The contact switch provides its signal upon release of pressure thereon, while the gravity ball tilt mechanism provides a signal upon shaking or rocking.
According to another aspect of the present invention, the apparatus for defacing banknotes contained within a banknote cassette in an Automated Teller Machine (ATM) upon a breach of security of the ATM, by releasing an indelible ink or dye under pressure into the banknote cassette includes a power cartridge as an initiator disposed adjacent to a non-fragmenting design rupture disc as the tank valve. The power cartridge is mounted in a cap of the pressurized tank containing the indelible ink. Rupture of the disc releases the ink into a delivery system in fluid communication with the pressurized tank, a distribution manifold operatively associated with the banknote cassette, and a connector coupled on one hand to the delivery system and releasably coupled on the other hand to the distribution manifold thereby providing fluid communication from the tank to the delivery system and the distribution manifold so the ink may deface the notes.
According to another aspect, when the banknote cassette is removed from the ATM, the connector automatically releases from the distribution manifold, and when the banknote cassette is returned to the ATM, the connector automatically couples to the distribution manifold.
BRIEF 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 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 an elevational view of a typical ATM;
FIG. 2 is a front partial cut-away view of the improved ATM of FIG. 1;
FIG. 3 is a side partial cut-away view of the improved ATM of FIG. 1;
FIG. 4 is a fragmentary view of the inside of the ATM of FIG. 1 showing an embodiment of the present document defacing apparatus;
FIG. 5 is an enlarged fragmentary view of the manifold and buttonhead coupling connection;
FIG. 6 is an enlarged fragmentary sectional view of the manifold as attached to an ATM money cassette and the buttonhead coupling connection thereto;
FIG. 7 is an elevational view of a mercury switch array according to the present invention;
FIG. 8 is a schematic of one embodiment of a mechanical and electrical actuating system for the present invention;
FIG. 9 is an enlarged fragmentary sectional view of the manifold as attached to an ATM money cassette having an alternative embodiment of the hose connection;
FIG. 10 is a schematic of a further embodiment of the actuating and releasing system;
FIG. 11 is an enlarged cutaway side view of the pressurized tank with an initiator and rupture disc according to another embodiment of the present invention;
FIG. 12 is an enlarged cutaway side view of the pressurized tank utilizing an explosive rupture disc according to another aspect of the present invention;
FIG. 13 is an enlarged elevation view of a pendulum tilt signal generating device;
FIG. 14 is an enlarged cutaway view of a gravity ball tilt signal generating device; and
FIG. 15 is a schematic of a contact switch signal generating device.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a typical stand-alone Automated Teller Machine (ATM) 20. At the outset it should be noted that the present invention is applicable to all types of ATMs and not only stand-alone units, however, a stand-alone ATM will be shown in the drawings. ATM 20 includes a housing 22 which encloses a modular electronic/mechanical unit 23, being the heart and brains of the ATM. Unit 23 includes a screen 24 for displaying information and choices to the user, an alpha/numeric keypad 26, a card access 28, and a money withdrawal/deposit port 30. Unit 23 is enclosed within a steel lined casing (not shown) that encloses all of the necessary hardware and software to operate the ATM. Generally, ATMs include a heating and cooling source for maintaining the working components, software, and hardware in working condition in all environments.
Referring now to FIG. 2, ATM 20 is shown in a cutaway view having two money cassettes 32 and 34, that are typical in the ATM industry, such as, for example, those shown in the Diebold catalogue submitted with the Information Disclosure Statement filed concurrently herewith. Although ATM 20 is shown having two money cassettes it should be understood that only one cassette or more than two cassettes may be accommodated in the ATM and are contemplated as within the scope of the present invention. Such cassettes may also be of any size and shape as the principles and operation of the present invention are equally applicable. Typically, cassettes 32 and 34 are for separate denominations of bills to dispense to the customer, say for example 20's and 10's in order to accommodate various cash amount requests. However, in some instances, ATMs dispense only one type of currency and thus cassettes 32, 34 may contain the same bill denomination. Cassettes 32 and 34 are aligned within ATM 20 via tracks 33a, 33b, 33c which rest on a stand 36. Tracks 33a-c guide cassettes 32, 34 because of the close tolerance needed between the cassette and the money dispensing mechanism, generally a vacuum type mechanism, for pulling the money from the cassette and delivering it to port 30. Cassettes 32 and 34 thus slide back and forth generally parallel with the floor of ATM 20 to allow replacement thereof when the money within the cassettes runs out.
In accordance with an aspect of the present invention, a pressurized tank 38 is disposed within housing 22 secured therein by a tank bracket 40. Tank 38 may be of any suitable type made to hold its contents at various pressures as, for example, in the range of 300-1000 psi. Here, tank 38 may be a 5 lb. Ansul® 1301 Halon tank. Disposed on the top portion of tank 38 is a pressure valve 42 for releasing the contents of tank 38 upon activation thereof. Pressure valve 42 is preferably a valve of the differential piston-type which leads itself to various modes of actuation, e.g. electric, pneumatic, manual. The primary material of valve 42 is brass which makes the valve somewhat corrosion resistant.
Valve 42, in the example, made and tested by the inventor as described hereinbelow under the head "Example", is shown in the Ansul® Halon 1301 Fire Suppression Systems--Installation, Operation, Recharge, Inspection and Maintenance Manual submitted with the Information Disclosure Statement filed concurrently herewith. Tank pressure acting on chamber areas on either side of the piston produces a positive sealing force such that the contents of the tank under pressure remains therein. The same pressure is thus attained on both sides of the piston due to a small vent or bleed hole through the piston. A free floating ball (not shown) acting as a one-way check valve allows minute flow through the piston; however, at actuation, when there is a large pressure difference, flow is checked. Actuation is accomplished by venting the pressure from the upper chamber (not shown) through a vent valve (not shown) this venting is accomplished by using any type of actuator, as described hereinbelow. The pressure is vented from the upper chamber, then the downward force is eliminated allowing the pressure in the tank to force the piston totally out of the flow passage to release the contents therein.
Disposed on top of valve 42 is an actuator 44 for actuating valve 42 in order to release the contents of tank 38. Actuator 44 is a solenoid type actuator which is also manually actuatable. Actuator 44 includes a longitudinal piston therein which is actuatable by a solenoid to move longitudinally to release the valve in pressure valve 42. Thus, actuator 44 may be energized by an electric signal to cause the solenoid to open valve 42, and alternatively actuator 44 may be manually actuated to open valve 42. Disposed at the top of actuator 44 is a lever actuator 46 which in conjunction with a cable system described hereinbelow, provides the manual actuation for actuator 44 by manually moving a pin (not shown) to actuate pressure valve 42.
Coupled to valve 42 are two hoses 48 and 50 which terminate in buttonhead couplers 52 and 56 respectively. Alternatively, the hoses may be stainless steel lines or conduits rather than hoses. This is because it is preferable to fix the connectors and lines leading to the banknote cassettes for ease of removing and installing the cassettes. Buttonhead couplers 52 and 56 may, for example, be Lincoln type couplers model 80933, as shown in the Lincoln catalogue, page 21, submitted with the Information Disclosure Statement filed concurrently herewith. The buttonhead couplers 52, 56 couple hoses 48 and 50 to manifolds 54 and 58 respectively on cassettes 32 and 34 such that the contents of tank 38 is in fluid communication with the cassettes 32, 34.
Referring now to FIG. 3 lever actuator 46 includes a pivoting lever or arm 60 which is attached to a cable 62. Cable 62 extends through an elbow joint 64 having an internal pulley which is affixed onto a tube or pipe 66 which is secured to ATM housing floor 68. Cable 62 thus runs through elbow 64 and pipe 66 and extends through housing floor 68 such that it is attached to a swivel bolt 70 which is fixedly attached to the ground or earth 72. As described hereinabove, pressure valve 42 is opened in order to release the contents (ink or dye) of tank 38 via a pin type valve of the same type as are used to fill and relieve pressure in pneumatic tires. Actuator 46 includes an internal pin which longitudinally moves within actuator 46 and when moved in a downward position by lever 60 causes valve 42 to relieve the pressure as hereinabove described to allow the ink within tank 38 to be released therefrom and into hoses 48 and 50. Lever 60 is caused to pivot on actuator 46 in order to release valve 42 upon an attempt to remove ATM 20 from its location. As can be appreciated in FIG. 3, as housing 22 is moved from its location, cable 62 being secured to ground 72, will pull pivot lever 60 in the direction of the arrow adjacent lever 60 to cause opening of valve 42 and the release of the contents of tank 38 in the money cassettes. Thus, the indelible ink contained under pressure within tank 38 is released into hoses 48 and 50 and into the cassettes 32, 34 when someone attempts to dislodge or remove ATM 20 from its location. As will be described in detail hereinbelow, the pressurized ink from tank 38 thus enters cassettes 32, 34 to stain the bank notes and/or documents contained within the cassettes. It should be noted that tank 38 is positioned near the front (screen side) of the ATM, while buttonhead couplers 56 releasably connects hose 50 to manifold 58. The buttonhead couplers 52 and 56 are identical in construction to each other. A section view of the buttonhead coupler 52 is shown later in FIG. 6. Those skilled in the art will recognize that the hose 48 can be connected to either side of the buttonhead coupler 52, upon removal of plug 120 and reversal of the coupling 116. In FIG. 6 the horseshoe shaped recess 123 opens opposite to the hose 48 as attached to the buttonhead coupler 52. In FIGS. 3 and 4 it is preferred to reverse the hose 48 so it is on the same side of the coupler 52 as the opening to the recess 123. In this fashion, an operator can tug on the hose 48 to ensure a firm connection between the coupler 52 and the buttonhead 102.
Referring now to FIG. 4, the overall system is shown in greater detail and the electrical actuation of valve 42 to release the pressurized ink from tank 38 will be described. It should be here appreciated that tank 38 is connected to hoses 48 and 50 via a discharge fitting 74 via a one-to-two line coupler 76, however, only one money cassette or a plurality of money cassettes may be attached to tank 38 as long as tank 38 has adequate pressure to supply and adequately soak the bank notes contained in each cassette which is provided by the present invention. Furthermore, in FIG. 4, tank 38 is positioned near the rear of ATM, with buttonhead couplers 52, 56 likewise positioned near the rear. Thus, it is apparent that tank 38 may be positioned anywhere within the ATM and in any orientation. Also, button couplers 52, 56 may be positioned anywhere along the respective manifold. Solenoid actuator 44 like actuator 46 includes a longitudinally extending piston which acts upon valve 42 to relieve the pressure and thus the contents of tank 38 upon downward movement of the actuating rod (not shown). Thus, when an electrical signal is supplied to solenoid actuator 44 valve 42 is actuated and the contents are then released from tank 38 into lines 48 and 50 through manifolds 54 and 58 into respective cassettes 32 and 34.
This electrical signal may be supplied to solenoid actuator 44 in a variety of ways. Such electrical means for releasing the contents of tank 38 may be used either alone or all together and in conjunction with the manual actuation via actuator 46, lever 60, and cable 62. The solenoid actuator 44 utilized in the present embodiment is actuated by a 12 volt 0.57 amp signal applied thereto. Thus, power of this type needs to be available. For this, each electrical component is attached to a power source (not shown) through power source line 80. Such power source may come from a step-down transformer tied into the electricity supplying the ATM with a battery backup should power be interrupted. Furthermore, the power may be supplied by a battery alone. It should be noted that a key switch 78 is utilized to turn off the electrical activation systems for changing the cassettes and/or doing repairs to the ATM.
One such electrical system consists of an infrared or other similar transmitter 82 and reflector 84 which projects an invisible infrared beam to reflector 84 which bounces back to infrared transmitter 82. As an example, transmitter 82 may be a Safe House Infrared Photorelay Sensor as sold by the Tandy Corporation. Should the beam be interrupted by removal of a money cassette, unit 82 sends a signal via line 86 to actuate solenoid actuator 44 to thereby release the ink under pressure within tank 38 to mark the bills contained within the cassettes. Unit 82 is connected to key switch 78 via line 87.
Another electrical actuation system is a mercury switch array or system 88 which is attached to ATM housing floor 68. Mercury switch array 88 is connected to the power source via lead 89 with key switch 78 interposed therebetween for deactivation of mercury switch array 88 during cassette change. Additionally referring to FIG. 7 there is shown an embodiment mercury switch array 88. Essentially, mercury switch array 88 includes a shaped metal plate 90 on which are disposed four mercury switches 92, 93, 94, and 95. Mercury switches 92-95 are oriented such that all four directions of movement away from a horizontal plane will activate one of the switches. Switches 92 and 93 are oppositely oriented such that movement in either direction away from the horizontal as indicated by arrow A causes contact to be made and a signal sent to solenoid actuator 44 via lead 98 in order to open valve 42 and release the dye under pressure within tank 38. Mercury switches 94 and 95 are oriented such that movement in a direction off the horizontal as indicated by arrow B will cause one of the switch contacts to be closed and send a signal via line 98 to solenoid actuator 44 to open valve 42 to thus relieve the contents of tank 38.
Another electrical component is a contact switch 100 which, when floor 68 is raised from the ground, will complete the circuit to send a signal via line 98 to solenoid actuator 44 to open valve 42 thereby releasing the contents of tank 38 into hoses 48 and 50.
An embodiment of a contact switch is shown in FIG. 15. A contact switch 200 consisting of a housing 201 includes a spring loaded plunger 202. The spring loaded plunger includes a contact head 203 that makes the electrical connection between connectors 204.
A further component may be utilized to generate the actuating signal, such as a pendulum tilt mechanism 210 is shown in FIG. 13. Such pendulum tilt mechanisms have been used in such items as pinball machines as a tilt sensing mechanism. The pendulum tilt mechanism 210 includes a hanger bracket 212 that supports a metal plumb bob 214 via a hook 216. The plumb bob includes a shaft 218 extending from its lower end. The shaft 218 extends through a hole 220 formed in a lower contact bracket 222. The hook 216 is coupled to one polarity of the power source, while the contact bracket is coupled to the other polarity of the power source. When the ATM is tilted, the shaft 218 will contact an edge of circle 220 of the contact bracket 222 to complete the electrical circuit and provide the necessary signal.
Additionally, a gravity ball tilt mechanism 230, as shown in FIG. 14, may be utilized to produce the actuation signal for the actuator. Such a gravity ball tilt mechanism is disclosed in U.S. Pat. No. 4,799,505, which is incorporated herein by reference. However, a short description of the main components and method of operation are as follows. The gravity ball tilt mechanism 230 includes a housing 232 that has a concave bottom portion 234. Threadedly received in the center of the concave bottom 234 is a threaded screw 236. The threaded screw 236 includes a concave upper end designed to hold a steel ball 238. A spring loaded T-contact 240 is naturally biased downwardly. The steel ball is placed in the concave portion 237 while the T-contact 240 is held in the open position. Once the ball 238 is in place, the T-bar 240 is lowered thereon. At this point, the T-bar does not make contact between lead brackets 242 and 244. Once the gravity ball tilt mechanism 230 is tilted enough, gravity will pull the steel ball away from the concave portion 237, whereupon the T-contact 240 will be biased downwardly to make contact between the contacts 242 and 244 thereby providing the actuating signal.
Thus, the present invention contemplates the use of mechanical/manual actuation and/or electrical actuation. The electrical actuation system is deactivated via key switch 78 in order for authorized personnel to exchange the money cassettes when necessary.
The connection of one embodiment of the electrical actuation system is shown in block diagram in FIG. 8. Essentially, the main power source 156 is connected to an AC adaptor or transformer 158 in order to step down the voltage and amperage to the required values. AC adaptor 158 thus supplies power to photo relay switch 162, mercury switch 164, and pressure switch 170. A battery back-up 160 may also be provided should power be interrupted. A key switch 166 is interposed between photo relay switch 162 and mercury switch 164/contact switch 170 so that the cassettes may be exchanged without triggering the system. Valve actuator 168 is operatively connected to key switch 166, photo relay switch 162, mercury switch 164, and pressure switch 170 such that actuation of any of these switches sends a signal to valve actuator 168 to cause the indelible ink under pressure within tank 38 to be dispensed into cassette 32 to blur documents 146 within chamber 144.
In a further embodiment in which actuation is initiated by an electrical signal and an electrical signal is caused to initiate the release of pressurized fluid from the tank, which is described hereinbelow, reference is made to FIG. 10 showing an alternative schematic embodiment. Rather than providing mechanical actuation or a mechanical/electrical actuation, it may be preferable to utilize an all electrical actuation system. Logic circuitry 250 consisting of well known components provides the linking of the various components and the generation of an output signal. An external power source 251, usually an A.C. source, may be converted through an A.C. adapter or transformer 252 to provide power to the control circuitry 250. Coupled to the control circuitry 250 is a battery backup supply 253 in case of power failure. A capacitor or other components may be needed within the control circuitry 250 when the control circuitry 250 is utilizing the battery backup. Such circuitry is well known in the art for initiators. Additionally, key switch 254 may be utilized to turn the system on and off for loading and unloading of the money cassette. Also coupled to the control circuitry 250 are signal generating devices mercury switch 255, pendulum tilt mechanism 256, pressure switch mechanism 257, ball tilt mechanism 258, and photo relay switch 259. Also coupled to the control circuitry are electrical leads 260 which coupled to the electrical initiating device 261 disposed on top of pressurized tank 262. Such an electrical initiating device to release the pressurized liquid will be described hereinbelow, with reference to FIGS. 11 and 12.
Referring now to FIG. 5, there is shown the manner of connection of hose 48 to manifold 54. It should be appreciated that FIG. 5 shows the connection of hose 48 to manifold 54 such that the contents of tank 38 may be in fluid communication with manifold 54 upon opening of valve 44 which is the same manner as the connection to the other cassettes. Hose 48 terminates with a standard button coupling 52 which slidably attaches to a standard buttonhead 102. Buttonhead 102 is threadedly received in manifold 54, while manifold 54 is secured via bolts 103 and/or a sealant, such as, for example, glue to cassette 32. It should here be appreciated that although manifold 54 is shown attached to the top of cassette 32 as a separate member, such manifold may be disposed inside cassette 32 or alternatively be formed as a part of the top wall of cassette 32. In this embodiment hose 48 is flexible and thus when cassette 32 is installed in tracks 33, coupling 52 must be manually slid onto buttonhead 102.
Referring now to FIG. 6 there is shown the hose connection manifold and cassette in a sectional showing the manner of connection of hose 48 with cassette 32 and the flow of dye through manifold 54 and into cassette 32. As previously stated, hose 48 terminates with a standard button coupling 52. Button coupling 52 comprises a housing 106 which defines an internal cavity 108. Cavity 108 extends from the upper surface of housing 106 and is plugged by a threaded cap 110. Hose 48 is coupled to coupling 116 having a bore 117 to allow fluid communication between hose 48 and chamber 108 of button coupling 52 via tapered bore 118. Coupling 116 is threadedly received in bore 118, thus fluid in hose 48 will enter button coupling 52 via bores 117 and 118. Housing 106 of button coupling 52 further includes a tapered bore 119 diametrically opposed to bore 118 which is sealed by a threaded nut or cap 120. Bore 119 may be used to connect another fluid source or to allow limited by-pass thereof. Disposed within chamber 108 is a spring 112 which, along with cap 110 biases a disk 114 in the downward direction. Tapered disk 114 is restrained from exiting chamber 108 by annular taper 124, which restricts disk 114 from downward movement but allows upward movement upon engagement with buttonhead 102 as described hereinbelow. Disposed around spring 112 is a washer 113 adjacent disk 114 for guiding spring 112. It should be appreciated that cap 110, when in the position shown in FIG. 6, compresses spring 112 so as to bias disk 114 in the downward position. Disk 114 includes a bore 115 which provides communication between chamber 108 and the outside of housing 106. In order to attach button coupling 52 to buttonhead 102, housing 106 includes a horseshoe shaped ledge 122 which defines a horseshoe shaped recess 123. Ledge 122 and recess 123 cooperatively act to retain annular portion 126 of buttonhead 102 by surrounding the same such that cylindrical portion 128 of buttonhead 102 is engaged with ledge 122. Thus, as button coupling 52 is slid onto buttonhead 102 in the direction as indicated by the arrow, disk 114 is upwardly biased such that a snaplike fit completes the coupling. Buttonhead 102 includes threads 130 and is threadingly received in upper wall 134 of manifold 54. An internal bore 132 of buttonhead 102 provides communication between button coupling 52 and interior chamber 138 defined within manifold 54. Lower wall 136 of manifold 54 includes a plurality of bores 142 extending therethrough and aligned with like bores 143 in top wall 140 of cassette 32. Thus, bores 142 and 143 cooperatively act to permit communication between chamber 138 of manifold 54 and chamber 144 of cassette 32. Disposed within chamber 144 are bank notes or documents 146 which will be blurred by the indelible ink upon actuation of the present system.
FIG. 6 thus shows the flow pattern of indelible ink which is under pressure and as it enters buttonhead 102 is caused to enter chamber 138 of manifold 54 to be released via bores 142 and 143 onto bank note 146 within chamber 144 of cassette 32.
Referring now to FIG. 9 an alternative embodiment regarding hose 48 and the connection of hose 48 to buttonhead 102 is disclosed. As mentioned hereinabove, in the embodiment shown in FIG. 6, hose 48 is flexible and thus when cassettes are changed, button coupling 52 must be manually removed from buttonhead 102 and thus subsequently manually replaced thereon. However, since the money cassettes are placed within the ATM with such close tolerances such that a vacuum can pull the money contained therein for dispensing to the user, such would lend itself to fixing button coupler 52 such that the process of removing the cartridge as indicated by arrow C in a horizontal direction and the replacement of a new cartridge in a horizontal direction as represented by arrow C automatically couples buttonhead 102 with button coupling 52. In this manner, button coupling 52 is mounted in a bracket 150, while bracket 150 is fixedly mounted to a shelf 148 via rivet or bolt 152 within the ATM. Thus, in this embodiment there is no manual connection and the simple process of loading and unloading the cassette uncouples and couples the present system. Furthermore, since pressurized ink is forced into the cassette container to blur the documents, the uncoupling and coupling of the present system is not hazardous or dangerous since there are no "live" charges or wires. For the embodiment shown in FIG. 9, hose 48 is a 5/8 inch I.D. hose coupled to a 1/2 inch hose shank 116 welded to buttonhead 120. Buttonhead 120 is modified at its inlet to accommodate the 1/2 inch hose shank. Inventor recommends that 12 or more bores 142 be formed in manifold 54 to align with a corresponding number of bores 143 in the top wall 140 of cassette 32. However, depending on pressure hose sizes and other factors, the number of bores may be increased or decreased.
An alternative embodiment of the ink releasing means is depicted in FIG. 11. Preferably, this embodiment is utilized in conjunction with the type of circuitry and signal generating means disclosed in FIG. 10 and described hereinabove. This system includes a pressurized tank of any suitable type made to hold its contents at various pressures as, for example, in the range of 300-1000 psi. Here, tank 270 is an 18 lb. tank. The tank includes an inner pick tube with a wall thickness of 4/32 of an inch that includes an air fill valve 274 and which is shown filled with an indelible dye or ink 275. Disposed on the top portion of the tank 270 is a cap or housing 276 constituting a valve for the tank along with the other components associated therewith which fits over an opening 277 of the pick up tube 272. Disposed in a side wall 278 of the cap 276 is a power cartridge initiator 280. The power cartridge initiator 280 is of a conventional type such as that manufactured by Hi-Shear Corporation. Such a power cartridge generates a gas upon electrical ignition through leads 282. This signal is provided through the control circuitry 250 as disclosed in FIG. 10. Also, a bulk head ignitor may be utilized as the pyrotechnic initiator, however, a power cartridge is preferred as the initiator. The cap 276 includes a threaded opening 284 opposite the power cartridge 280. Threadedly disposed in the opening 284 is a connector 286 coupled to the stainless steel conduit 288 for delivery of the ink once it is released into the manifold of the cassette. The coupling 286 includes a seal or rupture disc 290 that is preferably of a non-fragmenting design. Such rupture disc are available from LaMot Corporation of Continental Disc Company of Liberty, Mo. The rupture disc is of sufficient strength to contain the pressurized fluid 275 within the tank 270 while at the same time rupturable without fragmentation once the power cartridge 280 is initiated and the gas expelled therefrom contacts the ruptured disc. Therefore, in this embodiment a change of power cartridge and rupture disc are all that is needed to recharge or reactivate this system.
Referring to FIG. 12, an alternative embodiment of the all electrical initiation system is provided. A tank 300 of the same characteristics as tank 270 includes a pick up tube 302 and in which is housed a pressurized fluid 304. A housing 306 extends over an opening 305 of the pick up tube 302 and includes a threaded opening 308. A coupling 310 is sized to threadedly be received in opening 308 and is coupled to a stainless steel discharge conduit 312. Disposed in the opening 308 and held in place by the coupling 310 is an electrical explosive initiator disc 314 that includes electrical leads 315 that are coupled to the logic circuitry. The disc or seal 314 may take the form as represented by "A" and "B" in FIG. 12. Essentially, the seal includes a pinpoint explosive shaped charge that ruptures the disc upon the application of a suitable electrical signal.
OPERATION
The overall operation of the present system will now be described. With particular reference to FIG. 4, the system is set as described hereinabove and is ready to deface the bank notes and/or documents contained within cassettes 32 and 34 upon a breach of security, unauthorized entry or the attempted removal of the entire ATM. As previously described, if authorized personnel is to change the cassette, key switch 78 is utilized to deactivate the electronic signal generator such that the old cassettes may be removed and new cassettes put in. In the embodiment shown in FIG. 9, the authorized cassette exchanger merely pulls out the old cassettes and puts in the new cassettes since the coupling of the present system with the cassettes is automatic. However, where the hoses are flexible and are not attached so as to be automatic, each button connector 52 must be manually disengaged from buttonhead 102 or its respective button.
With the electrical system actuated, the present system may be triggered by any number of events, and safeguards may be built in such that either manual actuation or electronic actuation will take place upon a breach of security. Thus, in the scenario where the entire ATM, whether it is a stand-alone or wall unit, is moved from its foundation, cable 62 will move lever 60 so as to open valve 42. The opening of valve 42 thus allows the indelible ink contained under pressure within tank 38 to be expelled via hose 74 and into hoses 48 and 50. From that point, the fluid under pressure flows through the respective button coupling 52, 56 and into the respective button. From there the fluid enters the respective manifold 54, 58 and is forced under pressure through the plurality of bores 142 and 143 to thoroughly soak, blur, and deface documents 146. Concurrent with the manual actuation of valve 42 should the entire unit be removed from its foundation, pressure switch 100 will send an electrical signal to solenoid actuator 44 to actuate valve 42 resulting in the same scenario as described above. Furthermore, mercury switch array 88 will also send an electrical signal upon dislodgement against any horizontal plane to send a signal to solenoid actuator 44 to open valve 42. However, should the thief open the ATM, the breaking of the beam emanating from transmitter 82 will cause a signal to be sent to solenoid actuator 44 to open valve 42 with the result as described hereinabove.
The system of FIGS. 10-15 constituting an alternative embodiment of the present invention will now be described. If authorized personnel is to change the cassette, key switch 254 is utilized to deactivate the electronic circuitry and components such that the old cassettes may be removed and new cassettes put in. The key switch is then used to reactivate the system.
With the electrical system actuated, the present system may be triggered by any one of the signal generating devices, mercury switch 255, pendulum tilt 256, pressure switch 257, ball tilt mechanism 258, or photo relay switch 259. If any one of these signal generating devices provides a signal to the control circuitry 250, the control circuitry 250 generates an appropriate signal through leads 260 to initiate the power cartridge 280 or rupture disc 314.
In the case of the power cartridge 280, the electrical signal produces an explosion that creates a gas to rupture the disc 290. Rupturing of the disc 290 allows the pressurized fluid 275 to escape from tank 270 via pick up tube 272 and outlet 277 to flow through the line 288 and into the manifold and cassette thereby defacing the notes contained therein.
In the case of the explosive electrical disc 314, the disc is automatically ruptured upon the receipt of a signal through its leads 315 which allows the ink 304 contained within cylinder 300 to exit via pick up tube 302 and opening 305 through the discharge hose 312 and into the manifold and cassettes.
EXAMPLE
As an example of the above present invention, the inventor has utilized an Ansul® 5 lb. halon tank, as described hereinabove, filled with 3/4 gallons of rubbing alcohol and a temporary printing press type ink such as an ink pad ink that is water soluble and/or alcohol soluble and pressurized at a working pressure of 400 psi. A single 5/8 inch steel-lined I.D. hose was connected via appropriate fittings to the outlet of tank 38 and to a 1/2 inch hose shank (male) welded to the button coupling. The button coupling inlet was enlarged to 1/2 Inch to accommodate the hose shank, while the button coupling outlet was enlarged to 1/4 Inch. The spring and ball were both removed. The manifold was a 3/4 inch square tube having a six 1/8 inch bores therethrough corresponding to 1/8 inch bores in the cassette. Other parties and members were as stated hereinabove. In the test, sufficient pressure at 400 psi was produced with the stated hose and hole dimensions such that the present invention operated as described hereinabove. It should be understood, however, that a general range of 300 to 800 psi's can be used and with particular cassettes, different size tubing, and hole structures the present invention may modify accordingly.
As an example of the tank depicted in FIGS. 11 and 12, the ink should be a non-alcohol or flammable base in view of the type of initiators or liquid releasing devices utilized. The tank is generally a 300-1000 psi tank coupled to a stainless steel 3/8 inch conduit via a suitable connector 286. The non-fragmenting rupture disc 290 is easily replaceable as well as the threaded power cartridge 280.
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.
It should be appreciated that there are various configurations and methods of supplying the ink to the money cassettes. Such alternate forms may include the use of a turbine and impeller, an electric motor and impeller, an electric motor and piston positive displacement pump, an electric motor with a centrifugal impeller pump, or an electric motor with an eccentric rotary vane pump. Further, it is contemplated that the cartridge containing the ink may be actuated by an explosive charge and piston configuration, or a chemical reaction expansion created by heating, for example.
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An anti-theft device for Automated Teller Machines (ATMs) provides for the blurring or defacing of banknotes which are stored within ATM banknote cassettes/containers within the ATM upon a breach of security of the ATM, the breach of security being either a break-in attempt or the attempted removal of the entire ATM from its location. An indelible dye or ink, stored under pressure within a tank internal to the ATM unit, is caused to be released into a distribution manifold, which is integral with the banknote cassette and in communication with the interior thereof, upon receipt of an actuating signal. The actuating signal is preferably developed by an electrical device which triggers the release of the ink into the cassette. In one embodiment, connection and disconnection of the distribution manifold to the tank occurs automatically without user interface when cassettes are changed.
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TECHNICAL FIELD
[0001] The present invention relates to a side-flow type parallel-flow heat exchanger and an air conditioner equipped therewith.
BACKGROUND ART
[0002] A parallel-flow heat exchanger is widely used in, for example, vehicle air conditioners or outdoor units of air conditioners for buildings. The parallel-flow heat exchanger has a configuration in which a plurality of flat tubes are arranged between a plurality of header pipes such that a plurality of refrigerant passages in the flat tubes communicate with insides of the header pipes, and fins such as corrugated fins are disposed between the flat tubes.
[0003] FIG. 9 shows one example of a conventional side-flow type parallel-flow heat exchanger. In FIG. 9 , the upper side of the plane of the figure is the upper side of the heat exchanger, and the lower side of the plane of the figure is the lower side of the heat exchanger. In a heat exchanger 1 , two perpendicular header pipes 2 and 3 are arranged parallel to each other at an interval in the horizontal direction. Between the header pipes 2 and 3 , a plurality of horizontal flat tubes 4 are arranged at a predetermined pitch in the perpendicular direction. Each of the flat tubes 4 is an elongated metal member formed by extrusion and has inside thereof refrigerant passages 5 for a refrigerant to flow therethrough. The flat tubes 4 are arranged with the extrusion direction thereof, which is also the longitudinal direction thereof, set to be horizontal, and thus a direction in which a refrigerant flows through the refrigerant passages 5 is also horizontal. A plurality of refrigerant passages 5 of the same sectional shape and area are arranged in the depth direction in FIG. 9 , so that a perpendicular section of each of the flat tubes 4 has a harmonica-like shape. Each of the refrigerant passages 5 communicates with insides of the header pipes 2 and 3 . Corrugated fins 6 are disposed between adjacent ones of the flat tubes 4 .
[0004] The header pipes 2 and 3 , the flat tubes 4 , and the corrugated fins 6 are all made of a metal having high thermal conductivity, such as aluminum. The flat tubes 4 are fixed to the header pipes 2 and 3 by brazing or by welding, and the corrugated fins 6 are fixed to the flat tubes 4 also by brazing or by welding.
[0005] In the heat exchanger 1 , refrigerant gates 7 and 8 are provided only on the header pipe 3 side. Inside the header pipe 3 , two partition plates 9 a and 9 c are provided at an interval in the vertical direction. Inside the header pipe 2 , a partition plate 9 b is provided at a height intermediate between heights at which the partition plates 9 a and 9 c are provided, respectively.
[0006] When the heat exchanger 1 is used as an evaporator, a refrigerant flows in through the lower refrigerant gate 7 as shown by a solid line arrow in FIG. 9 . The refrigerant that has entered through the refrigerant gate 7 is blocked by the partition plate 9 a to be directed to the header pipe 2 via some of the flat tubes 4 . This flow of the refrigerant is indicated by a left-pointing block arrow. The refrigerant that has entered the header pipe 2 is blocked by the partition plate 9 b to be directed to the header pipe 3 via different ones of the flat tubes 4 . This flow of the refrigerant is indicated by a right-pointing block arrow. The refrigerant that has entered the header pipe 3 is blocked by the partition plate 9 c to be directed to the header pipe 2 again via still different ones of the flat tubes 4 . This flow of the refrigerant is indicated by another left-pointing block arrow. The refrigerant that has entered the header pipe 2 turns around to be directed to the header pipe 3 again via still different ones of the flat tubes 4 . This flow of the refrigerant is indicated by another right-pointing block arrow. The refrigerant that has entered the header pipe 3 flows out through the refrigerant gate 8 . In this manner, the refrigerant flows from bottom to top forming a zigzag passage. The herein described case of using three partition plates is merely an example. The number of partition plates used and a resulting number of times the flow of a refrigerant turns around can set arbitrarily as required.
[0007] When the heat exchanger 1 is used as a condenser, the flow direction of a refrigerant is reversed. That is, a refrigerant enters the header pipe 3 through the refrigerant gate 8 as shown by a dotted line arrow in FIG. 9 and then is blocked by the partition plate 9 c to be directed to the header pipe 2 via some of the flat tubes 4 . In the header pipe 2 , the refrigerant is blocked by the partition plate 9 b to be directed to the header pipe 3 via different ones of the flat tubes 4 . In the header pipe 3 , the refrigerant is blocked by the partition plate 9 a to be directed to the header pipe 2 again via still different ones of the flat tubes 4 . In the header pipe 2 , the refrigerant turns around to be directed to the header pipe 3 again via still different ones of the flat tubes 4 . Then, the refrigerant flows out through the refrigerant gate 7 as indicated by another dotted line arrow. In this manner, the refrigerant flows from top to bottom forming a zigzag passage.
[0008] When a heat exchanger is used as an evaporator, moisture in the atmosphere condenses on the cooled surface of the heat exchanger, and thus condensate water is formed. With a parallel-flow heat exchanger, if condensate water stays on the surfaces of flat tubes or of corrugated fins, a sectional area of an air flow passage is reduced due to the water, resulting in degraded heat exchange performance.
[0009] Condensate water turns into frost on the surface of the heat exchanger if the temperature is low. This process may even proceed from frost to ice. In this specification, the term “condensate water” is intended to encompass so-called defrost water, namely, water resulting from melting of such frost or ice.
[0010] Accumulation of condensate water is problematic particularly in a side-flow type parallel-flow heat exchanger. Patent Document 1 proposes a measure to promote drainage from a side-flow type parallel-flow heat exchanger.
[0011] In the heat exchanger disclosed in Patent Document 1, drainage guides are disposed in contact with corrugated fins on a side of the heat exchanger where condensate water gathers. The drainage guides are linear members and disposed to be tilted with respect to flat tubes. At least one of both ends of each of the drainage guides is led to a lower-end side or a side-end side of the heat exchanger.
LIST OF CITATIONS
Patent Literature
[0000]
Patent Document 1: JP-A-2007-285673
SUMMARY OF THE INVENTION
Technical Problem
[0013] It is an object of the present invention to improve a condensate water drainage capability of a side-flow type parallel-flow heat exchanger. It further is an object of the present invention to allow this effect to be achieved even in a case where the heat exchanger is disposed in a tilted state such that its surface on a side thereof where condensate water gathers is oriented downward.
Solution to the Problem
[0014] According to a preferred embodiment of the present invention, a heat exchanger according to the present invention is a side-flow type parallel-flow heat exchanger and includes: a plurality of header pipes that are arranged parallel to each other at an interval; a plurality of flat tubes that are arranged between the plurality of header pipes and each have inside thereof refrigerant passages communicating with insides of the header pipes; and corrugated fins that are disposed between adjacent ones of the flat tubes. In the heat exchanger, edges of the corrugated fins at a surface of the heat exchanger on a side thereof where condensate water gathers protrude from edges of the flat tubes. A linear water guide member is inserted into a gap between every adjacent ones of the protruding edges of the corrugated fins. A distance between the water guide member and the protruding edge of that one of the corrugated fins which is situated above the water guide member is such that surface tension of water is allowed to act therebetween. A V-shaped notch is formed at each edge of the corrugated fins at the protruding edges thereof.
[0015] According to a preferred embodiment of the present invention, in the heat exchanger configured as above, the V-shaped notch is formed at each of corrugation peaks and corrugation troughs of the corrugated fins.
[0016] According to a preferred embodiment of the present invention, in the heat exchanger configured as above, the V-shaped notch has such a notch depth as to expose at least part of one of the water guide members that is in contact with a portion of the corrugated fins where said V-shaped notch is formed.
[0017] According to a preferred embodiment of the present invention, in the heat exchanger configured as above, the V-shaped notch is formed in each perpendicular wall of the corrugated fins.
[0018] According to a preferred embodiment of the present invention, in the heat exchanger configured as above, the V-shaped notch is formed so that at least the deepest portion thereof extends deep to above that one of the water guide members which is situated immediately below that one of the corrugated fins in which said V-shaped notch is formed.
[0019] According to a preferred embodiment of the present invention, the heat exchanger configured above is incorporated in an outdoor unit of an air conditioner.
[0020] According to a preferred embodiment of the present invention, the heat exchanger configured as above is incorporated in an indoor unit of an air conditioner.
Advantageous Effects of the Invention
[0021] According to the present invention, in a side-flow type parallel-flow heat exchanger, edges of corrugated fins at a surface of the heat exchanger on a side thereof where condensate water gathers protrude from edges of flat tubes. A linear water guide member is inserted into a gap between every adjacent ones of the protruding edges of the corrugated fins. A distance between the water guide member and the protruding edge of that one of the corrugated fins which is situated above the water guide member is such that surface tension of water is allowed to act therebetween. Moreover, a V-shaped notch is formed at each edge of the corrugated fins at the protruding edges thereof. This configuration provides an effect of ensuring that surface tension of condensate water is allowed to act on the water guide member. There is also provided an effect that condensate water is drawn back inwardly from corners of the corrugated fins. Thus, even in a case where the heat exchanger is disposed in a tilted state such that its surface on a side thereof where condensate water gathers is oriented downward, a drainage function of the water guide member can be achieved sufficiently.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a partial front view of a heat exchanger according to a first embodiment of the present invention.
[0023] FIG. 2 is a partial top view of the heat exchanger according to the first embodiment.
[0024] FIG. 3 is a partial schematic sectional view of the heat exchanger according to the first embodiment.
[0025] FIG. 4 is a partial schematic sectional view showing a state where the heat exchanger according to the first embodiment is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward.
[0026] FIG. 5 is a partial schematic sectional view of a heat exchanger according to a second embodiment of the present invention.
[0027] FIG. 6 is a partial schematic sectional view showing a state where the heat exchanger according to the second embodiment is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward.
[0028] FIG. 7 is a schematic sectional view of an outdoor unit of an air conditioner equipped with the heat exchanger according to the present invention.
[0029] FIG. 8 is a schematic sectional view of an indoor unit of an air conditioner equipped with the heat exchanger according to the present invention.
[0030] FIG. 9 is a perpendicular sectional view showing a schematic structure of a conventional side-flow type parallel-flow heat exchanger.
[0031] FIG. 10 is a partial schematic sectional view of the conventional side-flow type parallel-flow heat exchanger.
[0032] FIG. 11 is a partial schematic sectional view showing a state where the conventional side-flow type parallel-flow heat exchanger is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward.
DESCRIPTION OF EMBODIMENTS
[0033] Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. 1 to 4 . In the following, constituent components functionally common to those in the conventional structure shown in FIG. 9 are denoted by the same reference symbols as in FIG. 9 , and descriptions thereof are omitted.
[0034] A drainage capability of a side-flow type parallel-flow heat exchanger 1 can be improved by forming the parallel-flow heat exchanger 1 to have a structure shown in FIG. 10 . That is, in the parallel-flow heat exchanger, edges of corrugated fins 6 at a surface of the heat exchanger on a side thereof where condensate water gathers protrude from edges of flat tubes 4 . A water guide member 10 is inserted into a gap G between every adjacent ones of protruding portions of the corrugated fins 6 . A distance between the water guide member 10 and the protruding edge of that one of the corrugated fins 6 which is situated above the water guide member 10 is such that surface tension of water is allowed to act therebetween.
[0035] As the water guide member 10 , any of the following can be used, for example: various types of water-absorbent and non-water-absorbent members allowing surface tension of condensate water to act on them, which include an assembly of fibers (preferably, synthetic fibers), namely, a so-called cord, a member formed by twisting wires or synthetic resin filaments into the shape of a double helix, a member formed by twisting wires or synthetic resin filaments into the shape of a coil spring, a member made by forming a metal or synthetic resin plate into a fine-pitch corrugated plate, a member formed in the shape of a drill bit by carving a spiral groove in the outer circumference of a metal or synthetic resin rod, a member made of a porous substance (water-absorbent member) such as a sponge, a member formed in the shape of a braid of cords, and a chain.
[0036] When condensate water is accumulated at the edges of the corrugated fins 6 , a bridging phenomenon (formation of a water film) occurs in planes at the edges of the corrugated fins 6 due to surface tension of the water. A bridging phenomenon occurs not only in the planes at the edges of the corrugated fins 6 but also between the water guide member 10 inserted under each of the corrugated fins 6 and the edge of the each of the corrugated fins 6 . Furthermore, a bridging phenomenon occurs also between the water guide member 10 and condensate water accumulated at the edge of that one of the corrugated fins 6 which is situated below the water guide member 10 . This series of bridging phenomena forms a water guide passage extending from an upper portion to a lower portion of the heat exchanger 1 and thus makes it possible to force the condensate water forming bridges among the corrugated fins 6 to flow downward.
[0037] It cannot be said, however, that the side-flow type parallel-flow heat exchanger 1 shown in FIG. 10 perfectly solves the problem of drainage. When, as shown in FIG. 11 , the parallel-flow heat exchanger 1 shown in FIG. 10 is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward, condensate water accumulated at the edges of the corrugated fins 6 undesirably drips from lower corners of corrugations of the corrugated fins 6 before moving onto the water guide members 10 under surface tension thereof. In a case where, for example, the heat exchanger 1 is incorporated in an indoor unit of an air conditioner and a cross flow fan is installed below the heat exchanger 1 , droplets of the water fly off in a mixed state with an air flow being blown out by the cross flow fan, thus causing user discomfort.
[0038] In order to solve this, the present invention has added some contrivance to the structure shown in FIG. 10 . That is, at protruding edges of corrugated fins 6 , a V-shaped notch 6 a (see FIG. 2 ) is formed at each of corrugation peaks (portions each denoted by “T” in FIG. 1 ) and corrugation troughs (portions each denoted by “B” in FIG. 1 ) of the corrugated fins 6 . The V-shaped notch 6 a has such a notch depth as to expose at least part of one of water guide members 10 that is in contact with a portion of the corrugated fins 6 where said V-shaped notch 6 a is formed.
[0039] While, as described earlier, various types of members can be used as the water guide member 10 , herein used is a strand of two wires. For prevention of galvanic corrosion, as a material of the wires, the same material as used for flat tubes 4 and for the corrugated fins 6 is used. It follows that, if the flat tubes 4 and the corrugated fins 6 are made of aluminum, wires used are also made of aluminum. The water guide member 10 has substantially the same length as that of each of the flat tubes 4 .
[0040] When the heat exchanger 1 according to the first embodiment is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward, it takes a posture shown in FIG. 4 . As shown by arrows in FIG. 4 , condensate water that has gathered at the edges of the corrugated fins 6 flows down toward each of the corrugation troughs of the corrugated fins 6 . Upon reaching the V-shaped notch 6 a , the condensate water immediately exerts surface tension on a portion of the water guide member 10 exposed from the V-shaped notch 6 a . This ensures that the condensate water moves onto the water guide member 10 .
[0041] The condensate water that has moved onto the water guide member 10 under the surface tension moves onto that one of the corrugated fins 6 which is situated below the water guide member 10 through the V-shaped notch 6 a formed at each corrugation peak thereof. In this manner, a water guide passage extending from an upper one of the corrugated fins 6 to a lower one of the corrugated fins 6 can be formed by a series of bridging phenomena. For purposes of collecting and draining condensate water, a water receiving and draining mechanism could be set up at a lowermost one of the corrugated fins 6 or at that one of the corrugated fins 6 which is situated slightly above the lowermost one.
[0042] According to the configuration of the first embodiment, there can be avoided a situation where condensate water drips also from the corrugated fins 6 other than the lowermost one thereof, and droplets of the water that has dripped fly off in a mixed state with an air flow being blown out by a cross flow fan disposed below the heat exchanger 1 , thus causing user discomfort.
[0043] FIGS. 5 and 6 show a second embodiment of the present invention. Also in the second embodiment, a V-shaped notch is formed at each edge of corrugated fins 6 at protruding edges thereof but at a different location than in the first embodiment. That is, at the protruding edges of the corrugated fins 6 , a V-shaped notch 6 b is formed at an edge of each perpendicular wall of the corrugated fins 6 . The V-shaped notch 6 b is formed so that at least the deepest portion thereof extends deep to above that one of water guide members 10 which is situated immediately below that one of the corrugated fins 6 in which said V-shaped notch 6 b is formed.
[0044] When a heat exchanger 1 according to the second embodiment is disposed to be tilted such that its surface on a side thereof where condensate water gathers is oriented downward, it takes a posture shown in FIG. 6 . As shown by arrows in FIG. 6 , condensate water formed at an upper portion of each of the corrugated fins 6 once moves toward a depth direction of the each of the corrugated fins 6 along an edge of the V-shaped notch 6 b and then flows down toward the water guide member 10 . Thus, unlike in the conventional structure shown in FIG. 11 , condensate water is prevented from directly dripping from lower corners of corrugations of the corrugated fins 6 . As a result, it is ensured that condensate water exerts surface tension on the water guide member 10 , so that a water guide passage extending from an upper one of the corrugated fins 6 to a lower one of the corrugated fins 6 can be formed by a series of bridging phenomena. For purposes of collecting and draining condensate water, a water receiving and draining mechanism could be set up at a lowermost one of the corrugated fins 6 or that one of the corrugated fins 6 which is situated slightly above the lowermost one.
[0045] According to the configuration of the second embodiment, there can be avoided a situation where condensate water drips also from the corrugated fins 6 other than the lowermost one thereof, and droplets of the water that has dripped fly off in a mixed state with an air flow being blown out by a cross flow fan disposed below the heat exchanger 1 , thus causing user discomfort.
[0046] It is possible to simultaneously implement the first embodiment and the second embodiment. That is, the corrugated fins 6 may have, in addition to the V-shaped notch 6 a formed at each of the corrugation peaks and corrugation troughs thereof, the V-shaped notch 6 b formed at each perpendicular wall thereof.
[0047] The V-shaped notches 6 a and 6 b need not be precisely V-shaped. Each of them may be rounded at the deepest portion thereof to be shaped like a character “U”.
[0048] The above-described heat exchanger 1 can be incorporated in an outdoor unit or an indoor unit of a separate type air conditioner. FIG. 7 shows an example in which the heat exchanger 1 is incorporated in the outdoor unit, and FIG. 8 shows an example in which the heat exchanger 1 is incorporated in the indoor unit.
[0049] An outdoor unit 20 shown in FIG. 7 includes a sheet-metal housing 20 a that is substantially rectangular in plan, longer sides of which constitute a front face 20 F and a back face 20 B, and shorter sides of which constitute a left side face 20 L and a right side face 20 R. An exhaust port 21 is formed in the front face 20 F, a back-face air intake port 22 is formed in the back face 20 B, and a side-face air intake port 23 is formed in the left side face 20 L. The exhaust port 21 is an assembly of a plurality of horizontal slit-shaped openings, and the back-face air intake port 22 and the side-face air intake port 23 are lattice-shaped openings. Four sheet-metal members that are the front face 20 F, the back face 20 B, the left side face 20 L, and the right side face 20 R, together with unshown top and bottom panels, form the box-shaped housing 20 a.
[0050] Inside the housing 20 a , a heat exchanger 1 that has an L-shaped thermal plane is disposed on an immediately inner side relative to the back-face air intake port 22 and the side-face air intake port 23 . A blower 24 is disposed between the heat exchanger 1 and the exhaust port 21 in order to forcibly cause heat exchange between the heat exchanger 1 and outdoor air. The blower 24 is formed by combining an electric motor 24 a with a propeller fan 24 b . In the housing 20 a , on an inner surface of the front face 20 F, a bell mouth 25 is fitted so as to surround the propeller fan 24 b for improved blowing efficiency. The housing 20 a includes a space on the inner side relative to the right-side face 20 R, which is isolated by a partition wall 26 from an air flow flowing from the back-face air intake port 22 to the exhaust port 21 , and a compressor 27 is accommodated in this space.
[0051] Condensate water formed in the heat exchanger 1 of the outdoor unit 20 reduces the area of an air flow passage, leading to deteriorated heat exchange performance. Moreover, when an outside air temperature is below the freezing point, the condensate water may even freeze to cause damage to the heat exchanger 1 . Thus, in the outdoor unit 20 , drainage of condensate water from the heat exchanger 1 is a crucial problem.
[0052] In the outdoor unit 20 , condensate water gathers on the windward side of the heat exchanger 1 . This is because, in the outdoor unit 20 , the heat exchanger 1 is installed in a state of not being tilted but standing substantially upright. When the heat exchanger 1 is used as an evaporator (as in, for example, a heating operation), heat exchange is performed more actively on the windward side than on the leeward side, and condensate water is accumulated on the windward side. Thus, the windward side constitutes a condensate-water gathering side.
[0053] Condensate water formed on the windward side rarely flows to the leeward side. When an outside air temperature is low, condensate water freezes to the heat exchanger 1 in the form of frost. An increased amount of frost necessitates a defrosting operation. During the defrosting operation, the blower 24 is stopped from operating, and thus water resulting from the defrosting operation flows mainly downward due to gravity without being affected by wind. Thus, providing the structures of the present invention described in Embodiments 1 and 2 at a surface of the heat exchanger 1 on the windward side enables quick drainage of condensate water and can prevent heat exchange performance from being degraded.
[0054] An indoor unit 30 shown in FIG. 8 includes a housing 30 a having the shape of a rectangular parallelepiped that is flat in the vertical direction. The housing 30 a is fitted to an unshown wall surface inside a room via a base 31 fixed to a back face of the housing 30 a . The housing 30 a has a blow-out port 32 at the front thereof and has, in a top face thereof, an intake port 33 that is an assembly of a plurality of slits or an opening partitioned in a lattice shape. The blow-out port 32 is provided with a cover 34 and a wind deflection plate 35 . The cover 34 and the wind deflection plate 35 both rotate in a perpendicular plane to be horizontal (in an open state) when the air conditioner is in operation and to be perpendicular (in a closed state) when the air conditioner is out of operation. A filter 36 that collects dust contained in taken-in air is disposed on the inner side relative to the intake port 33 .
[0055] On the inner side relative to the blow-out port 32 , a cross flow fan 40 for forming a blow-out air flow is disposed with an axis thereof set to be horizontal. The cross flow fan 40 is accommodated in a fan casing 41 and made to rotate in the direction indicated by an arrow in FIG. 8 by an unshown electric motor to form an air flow flowing in through the intake port 33 to be blown out through the blow-out port 32 .
[0056] A heat exchanger 1 is disposed behind the cross flow fan 40 . The heat exchanger 1 is disposed within the height of the fan casing 41 , in a tilted state where the cross flow fan 40 side thereof is set to be high.
[0057] In the indoor unit 30 , the lower surface of the heat exchanger 1 , which is on the leeward side, constitutes a condensate-water gathering side. A water guide member 10 is disposed at this leeward-side surface of the heat exchanger 1 , and a V-shaped notch 6 a or 6 b also is formed at each edge of corrugated fins 6 on this side.
[0058] The foregoing embodiments of the present invention are not intended to limit the scope of the present invention thereto, and various modifications can be made within the spirit of the invention.
INDUSTRIAL APPLICABILITY
[0059] The present invention is broadly applicable to side-flow type parallel-flow heat exchangers.
LIST OF REFERENCE SYMBOLS
[0000]
1 heat exchanger
2 , 3 header pipe
4 flat tube
5 refrigerant passage
6 corrugated fin
6 a , 6 b V-shaped notch
G gap
7 , 8 refrigerant gate
10 water guide member
20 outdoor unit
30 indoor unit
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A heat exchanger ( 1 ) is provided with header pipes ( 2, 3 ), a plurality of flat tubes ( 4 ) disposed between the header pipes, and corrugated fins ( 6 ) disposed between the flat tubes ( 4 ). The end of the corrugated fin at the surface on the side, on which condensed water gathers, of the heat exchanger protrudes from an end of the flat tube ( 4 ), and a linear water-conducting member ( 10 ) is inserted between a gap (G) formed between the protruding portions of the corrugated fins. The interval between the water-conducting member and the protruding end of the corrugated fin located thereon is a distance at which the surface tension of water can act therebetween. A V-shaped cut ( 6 a or 6 b ) is formed at the edge of the protruding end of the corrugated fin.
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[0001] This application claims priority based on provisional application 60/465,515 filed Apr. 28, 2003
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to fishing lines and lures but more particularly to a device which recuperates fishing lures that are stuck underwater.
[0004] 2. Background
[0005] Losing one's lure has been the bane of many fishermen over the years. Since some types of lures are rather expensive, it is sometimes distressing to have to cut one's fishing line because a lure got caught in some underwater log or other debris or vegetation. Sometimes the water is too deep or too cold or both to be able to conveniently get to the lure and unstuck it. There is therefore a need for a practical way of freeing a stuck fishing lure.
SUMMARY OF THE INVENTION
[0006] It is a main feature of this invention to provide for an inexpensive, practical and efficient way to free a fishing lure that is stuck underwater.
[0007] In order to do so, the invention uses some basic readily available components which are used to attach the fishing lure recuperator. The fishing lure recuperator is bent to form a loose noose around the fishing line and is retained in this noose configuration by a connector which is itself attached to a thin rope or twine. As long as the connector is made of metal, it will sink and drag the fishing lure recuperator with it. Once the fishing line recuperator has reached the lure, actually a spot just below it, the fishing lure recuperator will engage an insertion slot which funnels into a small grabber incision sized for a fishing line. In grabbing a hold of the fishing line in that way, it is possible to unstuck a fishing lure even if it often results in breaking the fishing line below the lure and losing the hook. At least, the lure and most of the fishing line is saved when otherwise, a strong pull could snap the line at any point between the reel and the hook, which is especially distressing when it is close to the reel and most of the line is lost which remains in the water and can snare ducks and other water borne birds as well as mammals swimmers and divers as well as motor boat propellers.
[0008] The foregoing and other objects, features, and advantages of this invention will become more readily apparent from the following detailed description of a preferred embodiment with reference to the accompanying drawings, wherein the preferred embodiment of the invention is shown and described, by way of examples. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
[0009] [0009]FIG. 1 Perspective view of the invention in context.
[0010] [0010]FIG. 2 Front elevation of the fishing lure recuperator opened and flattened.
[0011] [0011]FIG. 3 Front elevation detail of the area around the insertion slot.
[0012] [0012]FIG. 4 Top elevation of the fishing lure recuperator.
[0013] [0013]FIG. 5 Side elevation of the fishing lure recuperator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] A fishing lure recuperator ( 10 ) comprises a looped piece ( 11 ) (shown flattened in FIG. 2) having a length a width and two opposite ends ( 12 and 12 ′), and each opposite ends has a hole ( 14 , 14 ′). Halfway along the length of the looped piece ( 11 ) is an insertion slot ( 16 ) which funnels into a small grabber incision ( 18 ) sized for a fishing line ( 28 ).
[0015] Along the length of the looped piece ( 11 ) are two sides ( 20 , 20 ′) which are not parallel, rather, the side ( 20 ′) where the insertion slot ( 16 ) is to be found is gabled so that it forms a generally triangular shape wherein the apex of the gable is where the insertion slot ( 16 ) is located.
[0016] Besides the looped piece ( 11 ), a string or cord ( 24 ) is used for pulling on the looped piece from the surface. A connector means ( 22 ) releasably connects the string or cord ( 24 ) to the looped piece ( 11 ). The connector means ( 22 ) releasably connects through both holes ( 14 , 14 ′) of the looped piece ( 11 ) wherein which both holes ( 14 , 14 ′) stand relatively mated. The connector means ( 22 ) itself is fixedly attached to a cord ( 24 ) by way of a knot although any other attachment means, whether permanent or semi-permanent, can be used without departing from the scope of the invention. It should be understood that although the cord ( 24 ) and the connector means ( 22 ) are essential to the workings of the lure recuperator ( 10 ) and that they could be bought as part of a kit, the looped piece ( 10 ) itself is the key element and that the connector means can come in a variety of ways besides a bolt snap as shown in the figures without departing from the spirit of the invention. It is important that the lure recuperator ( 10 ) be able to sink and therefore a non buoyant object is preferred for the connector means ( 22 ) so that the lure recuperator ( 10 ) can sink as quickly as possible. Of course any additional non buoyant object, such as lead weight well known to fishermen, can be attached to the cord ( 24 ) to make it sink faster. The looped piece is generally made of metal that is not affected by water such as stainless steel but any other non buoyant material offering the strength and surability required is satisfactory.
[0017] A user finding his lure caught in some underwater object ( 100 ) such as a log or branch or other vegetation or impediment uses the lure recuperator ( 10 ) by wrapping it around the fishing line ( 28 ), installing the connector means ( 22 ) with the cord ( 24 ) attached and drops it so that the lure recuperator ( 10 ) slides along the fishing line as per FIG. 6 a . Once the lure recuperator ( 10 ) has reached a spot just below the stuck fishing lure ( 26 ), the user pulls lightly on the cord ( 24 ) so that the insertion slot ( 16 ) guides the small grabber incision ( 18 ) into seizing the lure ( 26 ), as per FIG. 6 b . Moreover, an angle ( 30 ) of between 9 to 25 degrees, formed within the bend of the looped piece ( 11 ) creates a shape which further contributes to maintaining the lure ( 26 ) within the grasp of the looped piece ( 11 ) during the critical moment that strong tension is put on the fishing line ( 28 ) which can eventually result in snapping the fishing line ( 28 ). This results in freeing the lure ( 26 ) which is then brought back to the surface by winding in the fishing line ( 28 ).
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A fishing lure recuperator comprised of a looped piece attached to a connector itself attached to a cord and which is slid down a fishing line in order to grab hold of a stuck fishing lure and pulling it up to the surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
A pinch valve sleeve for reducing the pressure of fluid flowing therethrough.
2. Description of the Prior Art
Pinch valve sleeves are generally tubular and are constructed of a flexible resilient elastomeric material. They are positioned in a valve body which is interprosed in a conduit, duct, pipe or tube, together with means to constrict the sleeve intermediate its ends so as to curtail, terminate, or control the flow of fluid through the conduit or the like. Usually, the valve sleeve is concentrically oriented within an outer rigid valve housing and the sleeve is constricted by suitable means which squeezes the sleeve inwardly to deform or collapse the same and thus provide a smaller fluid flow passage.
Normally, a pinch valve sleeve is made from pure gum rubber, neoprene, Buna, butyl rubber, Hypalon, polyurethane, Viton, Teflon or silicon rubber. Typically, any suitable flexible and resilient material of construction may be employed for the sleeve. However, a synthetic rubber such as Hypalon, Buna, neoprene, an elastomeric plastic, or natural rubber is preferred. Hypalon is a rubbery material obtained by the chlorination and sulfonation of polyethylene. Buna is a rubber substitute prepared by the polymerization of butadiene. Neoprene is polychloroprene made by the polymerization of chloroprene; e.g. neoprene is a generic name for synthetic rubbers made by polymerization of 2-chloro-1, 3-butadiene (prepared by the action of hydrogen chloride on monovinylacetylene).
Pinch valve constructions have been used in a wide variety of situations. More specifically, pinch valve constructions have been used in controlling the flow of, by way of example, solids in suspension (either in slurry or air-conveyed form), especially abrasive materials such as metallic ores, asbestos, fiber, sand, coal, sugar, wood chips or pulps, paper stock, plastic pellets, raw sewage, talc, cement, fly ash, as well as for conveyance of various fluent chemicals and foodstuffs.
In some situations where pinch valves are utilized, the material being conveyed through the conduit, duct, pipe, or tube in which the valve is interposed enters the valve sleeve under a great deal of pressure and it is desirable to reduce the flow pressure so that the material will flow into the pipe or conduit portion downstream of the valve at a lower pressure than upstream of the valve. Examples of situations where such a pressure differential between the portion of a pipe or conduit upstream of a pinch valve and those downstream of the valve are desirable are in the mining and chemical industries where materials are being conveyed in, for example, slurry form at high pressure and a means built into the pipeline or conduit system, which means is capable of reducing the line pressure with or without actuation by any separate mechanical or other arrangement, is required.
The pinch valve sleeves of the prior art are not useful for providing a reduction in pressure as described hereinabove because they are generally constructed in such a fashion that their inner surfaces, which bound the flow-through passage, are of a smooth configuration and, thus, the fluid passing through the sleeve is not impeded or interfered with in any fashion and exits from the outlet opening of the valve under the same pressure as it was under when it entered the valve. In order to decrease the pressure of the fluid flowing through the valve, the pinching means must be actuated to squeeze the valve sleeve and thus provide a smaller flow-through passage.
The applicant is not aware of prior art patents or publications relating to pinch valve sleeves with internal obstructions, but among the prior art patents relating to pinch valve constructions generally may be mentioned U.S. Pat. Nos. 2,167,952; 2,660,395; 3,588,034; and 4,172,580.
SUMMARY OF THE INVENTION
1. Objects of the Invention
It is the object of the present invention to provide an improved pinch valve sleeve construction.
Another object is to provide a pinch valve sleeve which is useful for reducing the pressure of the fluid flowing therethrough.
A further object is to provide a pinch valve sleeve which can act as a pressure-reducing component of a pipe, duct, conduit or tube without requiring actuation of the pinching means of the valve.
An additional object of the present invention is to provide a pinch valve sleeve which provides better flow control when the pinching mechanism is actuated to constrict the sleeve body than prior art pinch valve sleeves.
Still another object is to provide a pinch valve sleeve with a sleeve body having protrusions on its inner surface that impede fluid flow through the sleeve's flow-through passage.
Yet another object of the present invention is to provide a pressure-reducing pinch valve sleeve wherein the protrusions on the inner surface of the sleeve body comprise annular flanges, discrete knobs, or similar protuberances.
Yet an additional object of the present invention is to provide a pressure-reducing pinch valve sleeve having a venturi-shaped flow-through passage.
Still a further object is to provide a pressure-reducing pinch valve sleeve that can be easily removed and replaced when the inner surface of the sleeve body or the protrusions thereon have become worn.
These and other objects and advantages of the present invention will become evident from the description that follows.
2. Features of the Invention
The pinch valve sleeve of the present invention comprises a hollow, flexible, resilient sleeve body having an inner surface circumferentially bounding a flow-through passage, and a means for attaching the sleeve to adjacent sections of a pipeline or conduit system, for example, peripheral flanges at both ends of the sleeve body. The sleeve body has an ingress section adjacent to the inlet opening in the sleeve through which fluid enters the sleeve and an egress section adjacent to the outlet opening through which fluid exits the sleeve. The sleeve body also has a pinchable intermediate section situated between the ingress section and the egress section.
A fluid stream flowing through the pinch valve in which the sleeve is mounted flows successively through the inlet opening of the valve sleeve, the ingress section of the sleeve body, the intermediate section of the sleeve body, the egress section, and, finally, the outlet opening of the valve sleeve.
The inner surfaces of the ingress and egress sections of the valve sleeve body have a plurality of protrusions, e.g., annular flanges or knob-like protuberances, arranged axially along the flow-through passage. The inner surface of the pinchable intermediate section can similarly have protrusions thereon or can be free of protrusions and thus have a smooth configuration. The pinching mechanism of the valve will be actuated to constrict the valve sleeve in the area of the intermediate section, and the protrusions on the inner surface of that section, if any, do not interfere with the pinching action because the protrusions are of resilient, elastomeric material and can be substantially flattened under the pressure of the pinching members so that flow-through passage can effectively be entirely closed off when desired. In fact, the presence of the protrusions in the intermediate section enables better flow control when the pinching mechanism is actuated than is achieved with prior art valve sleeves.
It will be appreciated by those skilled in the art that fluid flowing through the inlet opening of the valve sleeve and into the ingress section under a given pressure will be impeded or interfered with by the protrusions situated on the inner surface of the ingress section of the sleeve body and turbulent eddies will be created as the fluid flows around and past said protrusions. The pressure of the fluid will thus be decreased and energy lost through the interference of the protrusions with the axial fluid flow. The fluid then passes through the intermediate section where it may again encounter protrusions arranged circumferentially about and axially of the inner surface of that section. The fluid subsequently encounters the protrusions on the inner surface of the egress section. The interference of all protrusions on the inner surface of the valve sleeve substantially decreases the pressure of the fluid so that the fluid exiting through the outlet opening of the sleeve is at a substantially lower pressure than the fluid entering into the inlet opening of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pinch valve sleeve embodying the present invention.
FIG. 2 is an enlarged sectional view taken substantially along line 2--2 of FIG. 1, showing in phantom lines a pair of movable pinching members constricting the valve sleeve.
FIG. 3 is an enlarged sectional view taken substantially along line 3--3 of FIG. 2.
FIG. 4 is an enlarged fragmentary perspective view of a portion of a non-central inner surface of the valve sleeve showing a hemispherical protrusion on said surface.
FIG. 5 is a view similar to FIG. 4, showing a hemiovoid protrusion on said surface.
FIG. 6 is a view similar to FIG. 4, showing a square pyramidal protrusion on said surface.
FIG. 7 is a partial sectional view, analogous to FIG. 2, of a pinch valve sleeve having knob-like protuberances even on the inner surface of the intermediate section of the sleeve body.
FIG. 8 is a view similar to FIG. 7, showing a series of inwardly extending annular flanges on the inner surface of the sleeve body.
FIG. 9 is a view similar to FIG. 7 of a valve sleeve whose sleeve body has an inner surface contoured to provide a venturi-shaped flow-through passage, said surface having knob-like protuberances in the ingress and egress sections of the sleeve body and no protuberances in the intermediate section thereof.
FIG. 10 is a view similar to FIG. 9, showing a series of annular flanges on said venturi-shaped inner surface, said flanges being situated along the entire length of the sleeve body, including the intermediate section thereof.
FIG. 11 is a view similar to FIG. 8, showing flanges on said inner surface of progressively greater outer annular radius as their proximity to the center of the sleeve increases.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly to FIG. 1, the pinch valve sleeve of the present invention is denoted generally as 10 and comprises a circular tubular sleeve body 12 with an inner surface 14 bounding a flow-through passage 16. The sleeve is adapted to be mounted in a conventional valve body B provided with pinching means. Opposed peripheral outwardly extending flanges 18 and 20 are molded or fabricated in one piece respectively to each end of the sleeve body 12. Flanges 18 and 20 are each provided with a plurality of randomly or equidistantly spaced equi-radial through holes 22 parallel to the longitudinal axis of the sleeve body 12, through which bolts or other fastening means may be passed to attach the flanges to flanges at the adjacent ends of pipe or conduit sections or to a coupling or fitting 13 shown in phantom in FIG. 2, thus positioning the valve sleeve 10 in a pipeline or conduit system and permitting fluid flow therethrough.
Although the use of peripheral flanges on the sleeve body is illustrated for connecting the sleeve to adjacent pipe or conduit sections, a variety of connecting means familiar to those skilled in the art may be utilized for the same purpose.
As shown in FIG. 2, the valve sleeve 10 has an inlet opening 24 through which fluid flows into the flow-through passage 16 when the valve sleeve has been positioned in a pipeline or conduit system as previously described, and an outlet opening 26 through which fluid exits the flow-through passage 16 of the valve sleeve 10. The sleeve body 12 comprises an ingress section 28 adjacent to the inlet opening 24, an egress section 30 adjacent to the inlet opening 26 and a pinchable intermediate section 32 situated between the ingress and egress sections.
Pursuant to the principal features of the invention, a plurality of protrusions in the form of radially inwardly extending discrete knob-like protuberances 34, shown in FIG. 2 as teeth having the configurations of rectangular solids, are provided on the inner surfaces 35 and 37 of the ingress and egress sections respectively and are disposed circumferentially about and axially along said sections 35 and 37. Moreover, as shown in FIG. 2, the protuberances 34 are positioned on the inner surface sections 35 and 37 in a circumferentially staggered array so that a portion of the fluid flow entering the ingress section 28 through the inlet opening 24 encounters a first group of protuberances 36 mounted on the inner surface section 35 and is diverted around said protuberances in an eddying pattern until it proceeds to flow through the gaps 38 between the protuberances 36 substantially in the direction of the outlet opening of the sleeve. A second group of protuberances 40 is provided downstream of the first group 36 and is oriented to obstruct and impede the straight line flow of fluid emerging from the gaps 38, causing the fluid to be diverted around the protuberances 40 and to flow in an eddying fashion until it can proceed through the gaps 42 between the protuberances 40. A third group of protuberances 44 is provided downstream of the protuberances 40 which will be encountered by the fluid flowing in a straight line through the gaps 42 between the protuberances 40 causing further impedance of the fluid flow.
Any number of such groups of protuberances can be arranged along the length of the inner surface of ingress section 28 and circumferentially staggered to cause successive sites of interference with the fluid flowing through the ingress section. The radial heights of the protuberances can vary quite widely; typically between about one-tenth to about one-third of the radius of the sleeve.
As illustrated in FIG. 2, the intermediate section 32 of the sleeve body 12 is free of protuberances on its inner surface and the fluid emerging from the ingress section is thus free to flow through the intermediate section 32 without any further hindrance.
A fragmentary phantom view is shown in FIG. 2 of a conventional pinching mechanism 46 having opposed transversely displaceable pinching members 48, 50 which may be relatively moved to constrict the intermediate section 32 of the valve sleeve body 12, thus obstructing fluid flow through the flow-through passage 16 up to the point where the intermediate section 32 of the valve sleeve body is totally closed, whereupon fluid flow through the sleeve is entirely stopped. A fully closed central section 32 is shown in phantom lines in FIG. 2.
The pinching action necessary to close the valve sleeve body 12 can also be provided by hydraulic or air pressure on the outer surface of the sleeve body generated by introducing pressurized fluid into the valve body B until the sleeve body has been constricted to the desired degree.
After the fluid emerges from intermediate section 32, it enters the egress section 30, shown in FIG. 2, which, in identical fashion to the ingress section 28, has successive, circumferentially staggered groups of protuberances provided on its inner surface 37 which cause eddying and turbulence and impede the fluid flow through the egress section 30.
The impedance of the fluid flow through the flow-through passage 16 which is caused by the protuberances 34 disposed around the inner surfaces 35 and 37 of the ingress section 28 and the egress section 30 effects a drop in the pressure of the fluid flowing through the passage 16 because of the energy that is dissipated when the fluid is diverted from its straight line flow and forced to eddy around each successive group of protuberances as the fluid proceeds downstream through the valve sleeve body 12. Thus, the fluid emerging from the outlet opening of the sleeve body 12 is at a lower fluid pressure than the fluid which enters the inlet opening of the valve sleeve body 12, even when the pinching mechanism 46 is not actuated to constrict the intermediate section 32 of the sleeve body 12 to any degree whatsoever.
FIG. 3 shows an enlarged view of the flow-through passage 16, looking axially down said passage through the inlet opening 24 of the sleeve body 12. The protuberances 34 which are oriented around the inner surfaces 35 and 37 of the ingress section 28 and the egress section 30 respectively in axially spaced staggered groups are shown to be circumferentially disposed about substantially the entire circumference of the flow-through passage so that a very large portion of the fluid flowing through the inlet opening 24 and subsequently through the flow-through passage 14 will encounter at least one protuberance and have its flow impeded before emerging from the outlet opening 26. Although a uniform axially spaced staggered circumferentially spaced array for the protuberances has been shown and described, other relative arrangements can be utilized.
FIGS. 4, 5, and 6 show various examples of shapes for the protuberances which are incorporated into the inner surface 14 of the valve sleeve body 12. Thus, in FIG. 4, a hemispherical protuberance 52 is showns. In FIG. 5, a hemi-ovoid protuberance 54 is shown. Finally, in FIG. 6, a square pyramidal protuberance 56 is shown which has its square base at the inner surface 14 of the valve sleeve body 12 and its apex extending radially and inwardly into the flow-through passage 16.
In accordance with another embodiment of the present invention, the valve sleeve body 12 may have protrusions on its inner surface 14 even in the intermediate section 32. In FIG. 7, for example, the inner surface 14 of the sleeve body 12 has a plurality of protrusions 34 in the intermediate section 32. The protrusions on the intermediate section 32 are sufficiently elastomeric and resilient to be substantially flattened under the pressure of the pinching mechanism. Moreover, excellent flow control can be achieved by constricting the intermediate section of the sleeve shown in FIG. 7 partially or entirely with the pinching mechanism.
The protrusions which are provided on the inner surface 14 of the valve sleeve body 12 in accordance with the present invention need not be discrete knob-like protuberances, but may also take a variety of other forms, including the form of inwardly extending annular flanges 58 spaced axially along the inner surface of the sleeve body, as shown in FIG. 8. As with the discrete knob-like protuberances, the annular flanges 58 can be provided only on the inner surfaces 35, 37 of the ingress section 28 and the egress section 30 of the sleeve body 12, or may be situated in the intermediate section 32 as well.
When annular flanges are provided on the inner surface 14 of the sleeve body, the flow-through passage 16 is divided into a series of alternating large-diameter chambers 60 and smaller-diameter chambers 62. The fluid flowing into the ingress section 28 through the inlet opening 24 first enters a large chamber 60 and then is forced to pass through a smaller chamber 62, whereby the pressure of the fluid is reduced. The pressure of the fluid is further reduced as it passes through the remainder of the ingress section 28, the intermediate section 32 and the egress section 30, because the fluid flow is repeatedly interfered with and impeded by the annular flanges 58 as it proceeds along the flow-through passage 16. Thus the fluid exiting the valve sleeve through the outlet opening 26 is under considerably lower pressure than the fluid entering the inlet opening 24.
Another embodiment of the present invention is illustrated in FIG. 9. The inner surface 14 of the sleeve body 12 is contoured to provide a venturi-shaped flow-through passage 16 with a narrow throat 64 substantially at the center of the sleeve body 12. In addition, knob-like protuberances 34 are provided on the inner surface 14 of the ingress section 28 and the egress section 30. Both the venturi-like shape of the flow-through passage and the protuberances 34 act to reduce the pressure of the fluid flowing therethrough.
As shown in FIG. 10, the inner surface 14 of the valve sleeve body 12 may be contoured to provide a venturi-like flow-through passage 16, and, in addition, have a series of annular flanges 58 spaced along the length of the sleeve body 12. As in the embodiment shown in FIG. 8, the flanges 58 divide the flow-through passage 16 into alternating large and smaller chambers, but because of the venturi-like shape of the flow-through passage, both the large chambers 60 and the smaller chambers 62 grow progressively smaller as their proximity to the narrow throat 64, which is substantially in the center of the valve sleeve body 12, increases. The combination of the venturi-shaped flow-through passage and the series of annular flanges 58 causes a substantial drop in pressure of fluid flowing through the valve sleeve.
In FIG. 11, a valve sleeve 10 is shown with a series of annular flanges 58 provided on the inner surface 14 of the sleeve body 12. The flanges 58 progressively increase in annular or outer radius as their proximity to the center of the valve sleeve body 12 increases. The flow-through passage 16 is thus divided into a series of large chambers 60 and smaller chambers 62, said large chambers remaining of constant diameter while said smaller chambers progressively decrease in diameter as their proximity to the center of the sleeve body increases.
In accordance with the preferred embodiments of the present invention, the pinch valve sleeve body 12 is molded or hand fabricated from any one of a variety of durable long-wearing resilient elastomeric materials, including those heretofore described. When the valve sleeve does become worn, however, it can be easily removed from the pipeline or conduit system by detaching the end flanges 18 and 20 from the adjacent pipe or conduit sections. A new valve sleeve can then be positioned in the valve body.
While the invention has been illustrated and described as a pinch valve sleeve operative for reducing the pressure of the fluid flowing therethrough in a pipeline or conduit system, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various mechanisms without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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A pinch valve sleeve for reducing the pressure of fluid flowing therethrough with or without actuation of the valve's pinching mechanism. The valve sleeve features an elongated hollow flexible resilient elastomeric sleeve body having an inner surface circumferentially bounding a flow-through passage and peripheral flanges at both ends suitable for attachment to a section of a pipeline or conduit system. The sleeve body has an ingress section adjacent to the inlet opening of the valve sleeve, an egress section at the outlet opening which permits fluid egress, and a pinchable intermediate section situated between the ingress and egress sections. The inner surface of the sleeve body has thereon a plurality of radially-extending, inwardly-directed protrusions operative for impeding fluid flow through the flow-through passage of the sleeve, thus reducing the pressure so that the pressure of the fluid which exits through the outlet opening is lower than the pressure of the fluid entering the inlet opening.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention is directed to a dispenser of the type used in dispensing liquid from a container attached to the dispenser. In particular, the dispenser of the present invention is capable of selectively alternating the pattern of the liquid discharged between a foam and a spray discharge pattern. Further, the nozzle of the dispenser of the present invention is capable of being positioned alternately in "on" and "off" positions wherein the dispenser is permitted and inhibited from dispensing the liquid, respectively. In an alternative embodiment the dispenser is selectable between spray and stream patterns, as well as, between "on" and "off" positions.
(2) Description of the Related Art
There are numerous issued patents directed to dispensers having variable discharge patterns. Generally, a dispenser of the type involved in the present invention is a relatively low-cost, hand-held device which may be operated by pulling the trigger to pump a liquid substance from the interior of a container attached to the dispenser and through a nozzle at the front of the dispenser. Dispensers of this general type have a variety of features which have become well-known in the industry. For example, many of these dispensers include a horizontally aligned or an inclined pump which may be actuated using a trigger pivotally attached to the dispenser housing. This type of dispenser is frequently referred to as a trigger sprayer. Another type of dispenser has a vertically reciprocating pump which may be actuated with the index finger to dispense liquid as a stream or a spray. This type of dispenser is frequently referred to as a finger type pump. Still another type of dispenser comprises a container and a manually operated valve where the fluid contents of the container are pressurized. When the valve is opened, the fluid is dispensed. This type of fluid dispenser is frequently referred to as an aerosol dispenser. Nonetheless, the selectable discharge pattern apparatus of the present invention is equally well-suited for use with any of these aforementioned types of fluid dispensers, as well as, most other types of fluid dispensers.
Regardless of the type of dispenser used, some of the liquids which are dispensed through the dispensers work best when applied as a spray, and other liquids work best when applied as a foam. Still other liquids sometimes work best both as a spray and as a foam, depending upon the particular characteristics which are peculiar to the application. Thus, there is a need in the fluid dispenser art for liquid dispensers which are capable of alternately discharging the liquid in a spray discharge pattern and in a foam discharge pattern. Likewise, some liquids work best for some applications when dispensed as a spray and for other applications they work best when dispensed as a stream. Thus, there is also a need in the art for liquid dispensers which are capable of alternately discharging the liquid in a spray discharge pattern and in a stream discharge pattern.
Further, it is sometimes desirable to inhibit the flow of liquid through the dispenser. For instance, when the dispenser is being stored or transported, should the dispenser and attached container be turned on their sides or inverted, it is desirable that the dispenser not leak the container contents. Thus, there is a need in the dispenser art for dispensers which are configured to alternately permit and inhibit the liquid to be dispensed. When the liquid is permitted to be dispensed, the dispenser is said to be in the "on" position and when the liquid is inhibited from being dispensed, the dispenser is said to be in the "off" position.
U.S. Pat. No. 4,350,298 of Tada discloses several embodiments of fluid dispensers. The embodiment shown in FIGS. 1-4 of that patent is a typical trigger sprayer having an orifice configured to dispense a liquid substance as a spray. A foam generator comprised of a door having a hollow bore extending therefrom is pivotally connected to the trigger sprayer housing. At one end of the bore is a grate and at the other end of the bore are four equally-spaced openings. The foam generator may be pivoted to a foaming position wherein the bore is directly in front of the nozzle orifice. When the generator is in the foaming position, the spray discharged through the nozzle orifice impinges upon the interior surface of the bore so that a turbulence is generated in the liquid spray. The openings in the bore permit air to enter the bore and to become entrapped in the liquid spray and thereby aerate the liquid and form a foam. Thus, the trigger sprayer is capable of dispensing a liquid in a spray discharge pattern and in a foam discharge pattern. However, sprayers of this type frequently do not have the capability of alternating between "on" and "off" positions. Therefore, liquid may unintentionally leak from the trigger sprayer.
U.S. Pat. No. 4,706,888 of Dobbs also discloses a trigger sprayer which is capable of alternating discharge patterns. This trigger sprayer includes a nozzle which rotates relative to the housing between "on" and "off" positions, as well as, between stream and spray discharge patterns. Both the nozzle and housing include axial slots which alternatively align and are displaced from each other as the nozzle is rotated relative to the housing. The slots in the housing lead to a recess at the front of the housing. Some of the slots in the housing enter the recess through radial slots and others enter the recess through tangential slots. When the slots in the housing and nozzle are displaced from each other, the trigger sprayer is in the "off" position. When the slots in the housing align with the axial nozzle slots which communicate with the radial slots, the sprayer is in the "on" position and the liquid is dispensed as a stream. When the slots in the housing align with the axial nozzle slots which communicate with the tangential slots, the sprayer is again in the "on" position, but the liquid is dispensed as a spray having a conical pattern as is well known in the art. Thus, the sprayer is capable of being positioned in both "on" and "off" positions, as well as, dispensing liquid in either a spray or a stream discharge pattern. However, sprayers of this type frequently do not have a capability of dispensing liquid as a foam.
U.S. Pat. No. 4,730,775 of Maas discloses yet another prior art trigger sprayer. This sprayer has a nozzle which rotates between an "off" position and an "on" position in which the liquid is dispensed as a spray. The trigger sprayer also has a detachable foam generator which may be inserted into the sprayer nozzle to cause the liquid to be discharged as a foam. Alternately, the foam generator may be removed from the nozzle to permit the liquid to be dispensed in a spray pattern. However, because in sprayers of this type the foam generator is separate from the sprayer, there is a risk of losing the foam generator, thereby eliminating the ability of the sprayer to generate a foam from the dispensed liquid.
U.S. Pat. No. 4,779,803 of Corsette discloses another type of trigger sprayer having a rotatable nozzle which may be rotated to alternate "on" and "off" positions, as well as, between stream and spray discharge patterns as described above. In addition, this trigger sprayer includes a plate having an orifice which may be moved forward and backward between a foaming and non-foaming position. When in the non-foaming position, the plate is pushed rearward to a position adjacent to the nozzle orifice so that the plate does not interfere with the liquid being dispensed. When in the foaming position, the plate is spaced forward of the plane of the nozzle orifice so that the plate interferes with the outer flowstreams of the spray being discharged from the nozzle orifice. When the plate is in the foaming position, the spray strikes the plate creating a turbulence in the spray and aerating the spray to dispense the liquid as a foam. Thus, three different discharge patterns are possible; the nozzle may be rotated between stream and spray discharge patterns and the plate may be retracted or extended to alternate between spray and foam discharge patterns. Further, the nozzle may be rotated to place the liquid dispenser in "on" and "off" positions to alternately permit and inhibit the liquid to be dispensed.
U.S. Pat. No. 4,890,792 of Martin et al. discloses a trigger sprayer having a rotatable nozzle. A plate having a grate at one location in the plate and an open hole at another is pivotally connected within the nozzle. The plate is connected to the nozzle so that as the nozzle is rotated, the plate pivots to alternately align the grate or hole with the nozzle orifice. When the hole is aligned with the nozzle orifice, the liquid is discharged from the nozzle in a spray pattern. When the grate is aligned with the orifice, the liquid strikes the grate creating a turbulence and dispensing the liquid as a foam. The nozzle may be further rotated to switch the liquid dispenser between "on" and "off" positions.
SUMMARY OF THE INVENTION
The fluid dispenser of the present invention includes a rotatable nozzle having an orifice through which the liquid is dispensed. The nozzle may be rotated between "on" and "off" positions to permit and inhibit the dispensing of the liquid, respectively. When the nozzle is in the "on" position, liquid is dispensed through the orifice in a spray discharge pattern. In one embodiment, a foam generator is provided on a pivoting door mounted on the nozzle forward of the nozzle orifice. The generator includes a tubular bore on the door. The tubular bore extends rearwardly to the nozzle orifice when the door is pivoted downwardly to its foaming position in front of the nozzle orifice. The spray of liquid from the nozzle orifice impinges on the inner surface of the bore and creates a turbulence in the liquid as it is sprayed from the orifice. Openings extend into the bore to permit air to enter the bore and aerate the liquid thereby enhancing the foaming of the liquid. The door may also be pivoted upwardly so that the bore is displaced from the nozzle orifice and positioned in its non-foaming position where the liquid is dispensed from the nozzle orifice as a spray without contacting the tubular bore. Thus, liquid may be dispensed from the fluid dispenser of the present invention as a foam or as a spray, and the nozzle may be positioned in "on" and "off" positions.
In an alternate embodiment, a stream generator is provided on a pivoting door mounted on the nozzle in place of the foam generator. This generator includes a narrow, straight passage through the door. The passage extends rearwardly to the nozzle orifice when the door is pivoted downwardly to its stream position in front of the nozzle orifice. The liquid discharged from the nozzle orifice is consolidated and accelerated to form a stream of liquid. The door may also be pivoted upwardly so that the bore is displaced from the nozzle orifice and positioned in its spray position. Thus, the liquid may be dispensed from the fluid dispenser of the alternate embodiment as a stream or as a spray, and the nozzle may be positioned in "on" and "off" positions.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the present invention are revealed in the following Detailed Description of the Preferred Embodiment of the invention and in the drawing figures wherein:
FIG. 1 is a side elevation view of a fluid dispenser of the present invention having a selectable foam/spray, on/off nozzle;
FIG. 2 is a cross-sectional view of the foam/spray, on/off nozzle of the present invention shown with the nozzle in the "on" position and the foam generator in the foaming position;
FIG. 3 is a cross-sectional view of the foam/spray, on/off nozzle taken in the plane of line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view of the nozzle taken in the plane of line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view of the nozzle taken in the plane of line 5--5 of FIG. 2;
FIG. 6 is a cross-sectional view of the nozzle taken in the plane of line 6--6 of FIG. 2;
FIG. 7 is a cross-sectional view of the stream/spray, on/off nozzle of the alternate embodiment with the nozzle shown in the on position and the stream generator in the spray position; and
FIG. 8 is a cross-sectional view of the stream/spray, on/off nozzle shown with the nozzle in the "on" position and the stream generator in the stream position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As best seen in FIG. 1, the fluid dispenser 20 of the preferred embodiment is generally comprised of a container 22 and a dispenser head 24 fastened to the container with a threaded closure 26. Although there are many types of fluid dispensers 20 to which the present invention may be adapted without departing from the scope of this invention, the dispenser of the preferred embodiment is of the trigger sprayer type.
A typical trigger sprayer includes a housing 30 having a nozzle 32 through which a liquid is dispensed. The nozzle 32 defines the front 34 of the housing 30 which the user directs away from himself or herself and toward the target area where the liquid is to be dispensed. A trigger 36 is pivotally connected to the housing 30 and is operatively connected to a pump 38 located within the housing. The trigger may be reciprocated backward and forward in actuating the pump. A passage 40 extends through the housing 30 between the container 22 and the nozzle 32 and provides fluid communication between the container and nozzle. The pump 38 is located along the passage 40 and draws the liquid from the container 22 and pumps the liquid through the passage to the nozzle 32 upon actuation of the trigger.
The elements of the fluid dispenser 20 described above are typical of the prior art fluid dispensers and are well known in the art. Thus, these elements will not be described in further detail. However, a few of the elements of the fluid dispenser 20 of the preferred embodiment are novel and especially adapted for use with the nozzle 32 of the present invention. As shown in FIG. 2, the end of passage 40 adjacent the semiannular opening 50 is the liquid outlet end of a fluid discharge passage 42 which extends through the sprayer housing 30 to a liquid inlet opening (not shown) at its opposite end. The inlet opening is formed as a priming valve seat as is conventional in many trigger sprayers. A priming valve stem 44 having a T-shaped cross-section is positioned in the discharge passage 42. This stem 44 is adapted to retain a valve body (not shown) against the valve seat (not shown) at the rearward end or inlet end of the fluid discharge passage 42 to only permit liquid to pass through the discharge passage in a forward-traveling direction, as is well-known in the art. Thus, as the pump 38 is cycled between compression and suction strokes, the liquid will not be drawn rearwardly through the discharge passage 42 and into the pump on the suction stroke, but rather will be drawn from the container 22. On the compression stroke, the liquid will be pumped through the discharge passage 42 and out the semiannular opening 50 to the nozzle 32. The stem 44 T-shaped cross section has four fins 46 spacially arranged around the stem. The fins 46 fixedly center the stem in the discharge passage 42 and permit liquid to travel through the discharge passage between the fins of the stem.
A semiannular opening 50 is formed at the front 34 of the housing 30 where the fluid exits the passage 40 as seen in FIG. 6. A cylindrical projection 52 extends forward from the housing and is centered around the centerline of the arc of the semiannular opening 50. The cylindrical projection 52 also includes a socket 48 for axially retaining and radially centering the forward end of the priming valve stem 44. This projection 52 includes two axial grooves 54 which are equally spaced about the circumference and which extend lengthwise along a portion of the length of the projection 52 to a distal end 56 of the projection. A recess 58 is formed at the distal end of the projection 52 as shown in FIGS. 2 & 4. The intersection of the axial grooves 54 with the recess 58 forms two tangential grooves 60 that extend radially from the axial grooves 54 to the circular recess 58 and form a swirl chamber 62 in combination with the recess. As the name implies, the swirl chamber 62 causes liquid passing through the chamber to spin and thereby gives the liquid a radial velocity component as it exits the fluid dispenser. The radial velocity component causes the liquid to be dispensed in a conical spray discharge pattern rather than in a stream discharge pattern as would occur if the liquid had no radial velocity component from its spinning.
A cylindrical bushing 64 having an enlarged external diameter portion 66 near its distal end 68 concentrically surrounds the cylindrical projection 52. An annular chamber 70 is formed between the exterior of cylindrical projection 52 and the interior of the cylindrical bushing 64. As the liquid pumped by the dispenser exits the passage 40 through the semiannular opening 50 it enters the annular chamber 70.
The nozzle 32 is rotatably attached to the front 34 of the housing 30 about the cylindrical projection 52 and cylindrical bushing 64. The nozzle 32 includes a cylindrical tube 90 which is sized to fit around the cylindrical projection 52. The interior diameter of the tube 90 is matched to the exterior diameter of the projection 52 to inhibit fluid from easily passing between the tube and projection, but to permit the tube to rotate about the projection without any appreciable resistance. Two axial slots 92 are formed in the interior surface of the end of the tube and are equally spaced about the circumference of the tube 90. Depending upon the rotational position of the nozzle 32 relative to the housing 30, the slots 92 may align with the axial grooves 54. When the slots 92 align with the grooves 54, the nozzle is said to be in the "on" or open position. The liquid is permitted to exit the annular chamber 70 through the slot 92 and pass through the axial grooves 54 to enter the swirl chamber 62 when the nozzle is in the "on" position. When the slots 92 are not aligned or are displaced from the grooves 54, the nozzle is said to be in the "off" or closed position wherein the liquid is inhibited from passing through the axial grooves 54 to the swirl chamber 62.
The tube 90 has an end wall 94 which rests against the distal end 56 of the projection 52 adjacent the swirl chamber 62. An orifice 96 extends through the end wall 94 immediately in front of the swirl chamber 62 as shown in FIG. 2. The upstream end 98 of the orifice 96 may be rounded to reduce fluid resistance. Therefore, the fluid is discharged with more power and propelled over a greater distance than would otherwise occur if the upstream end had sharp corners. Further, the rearward side 100 of the end wall 94 may include a circular boss 102 sized to tightly fit within the inner diameter of the swirl chamber 62.
The nozzle 32 includes an outer cylindrical wall 110 which is spaced outwardly from the cylindrical tube 90 by an annular flange 112 extending outward from the cylindrical tube 90. The inner diameter of the outer wall 110 includes a reduced diameter section 114 which is configured to engage the outer surface of the cylindrical bushing 64 immediately behind the enlarged diameter portion 66 of the bushing, thereby mounting the nozzle 32 for rotation on the housing 30. This bushing 64 and outer wall 110 configuration permits the nozzle 32 to rotate relative to the housing 30 but prevents the nozzle from becoming axially disengaged from the housing. An annular sealing sleeve 116 extends rearwardly from the annular flange 112 and engages against the inner surface of the cylindrical bushing 64 to prevent liquid from passing from the annular chamber 70 between the interface of the nozzle and housing in the vicinity of the cylindrical bushing 64. An annular space 118 is formed between the outer wall 110 and the sealing sleeve 116 into which the cylindrical bushing 64 is inserted in assembling the nozzle 32 to the housing 30. The rearward ends 120, 122 of the reduced diameter section 114 and the sealing sleeve 116 are chamfered to ease insertion of the cylindrical bushing 64 into the annular space 118 during the initial assembly.
A tubular portion 130 of the nozzle 32 extends forwardly from the annular flange 112. Hinged to this portion 130 is a foam generator 132 which is pivotally connected to the tubular portion 130 by a living hinge 134. The foam generator 132 is comprised of a planar door 136 having a cylindrical tube 138 extending rearwardly from the door when in the foaming position as shown in FIG. 2. The cylindrical tube 138 includes a cylindrical bore 140 having four equally spaced openings 142 around its periphery adjacent the distal end 144 of the bore 140. The openings 142 are formed as rectilinear slots configured to permit air to pass between the bore 140 and outer diameter of the cylindrical tube 90 when the foam generator 132 is in the foaming position. As shown in FIG. 2, the door 136 extends downwardly past the tubular portion 130 of the nozzle 32 when the foam generator is in the foaming position. A tab 146 at the bottom of the door as shown in FIG. 2, may be gripped by a user to pivot the generator between the foaming position shown and a non-foaming position wherein the door extends upwardly from the tubular portion 130.
To use the spray dispenser of the preferred embodiment, the user must first turn the nozzle with respect to the housing such that the axial slots 90 in the nozzle align with the axial grooves 54 in the housing projection. This permits liquid entering the annular cavity 70 to pass through the axial slots 90 to the axial grooves 54 then through the tangential grooves 60 and into the swirl chamber 58 where it is swirled before being dispensed through the nozzle orifice 96 as a spray. When the door is in the non-foaming position, the spray exits the nozzle undisturbed. However, when the door is in the foaming position, the outer flowstreams of the spray impinge the inner surface of the bore 140 and are directed back toward the centerline of the spray so that a turbulence is created in the spray. Because the fluid being dispensed through the liquid dispenser is a foaming liquid, the turbulence entraps air in the liquid and the liquid exits the nozzle as a foam. The air entrapment is further enhanced by aeration due to air being drawn in from the exterior of the nozzle through the openings in the foam generator to the bore. To turn the nozzle to the off position, the user rotates the nozzle about the nozzle centerline to displace the axial slots 92 in the nozzle tube from the axial grooves 54 in the housing projection so that liquid cannot pass through the slots and into the swirl chamber.
An alternate embodiment is shown in FIGS. 7 and 8. This embodiment is similar to that disclosed above and shown in FIG. 2 except that a stream generator is substituted for the foam generator 132. Otherwise, with a few minor exceptions, the embodiment of FIGS. 7 and 8 is identical to that of FIG. 2. The common features will not be described again for brevity. Similar features of the embodiments will be identically numbered for convenience and clarity.
As with the previously described embodiment, the nozzle 32 includes a cylindrical tube 90 having an end wall 94. However, the end wall 94 of the alternate embodiment includes a frustoconical recess 152 which surrounds the orifice 96 extending through the wall. The stream generator 150 seats within this recess 152 when in the stream position shown in FIG. 8.
The tubular portion 130 of the nozzle 32 extends forwardly from the annular flange 112 as with the previously described embodiment, and the stream generator 150 is pivotally connected to the tubular portion by a living hinge 134. The stream generator 150 is comprised of a substantially planar door 154 having a frustoconical protrusion 156 extending rearwardly from the door when in the stream position as shown in FIG. 8 to seal against the frustoconical recess 152. The projection 156 includes a straight passage 158 having three sections 160, 162, 164. The rearward most section 160 when the door is in the stream position has a diameter slightly larger than the diameter of the orifice 96, the intermediate section 162 has a diameter generally equal to the orifice, and the forward section 164 has a diameter slightly smaller than the diameter of the orifice. The graduated passage 158 formed by the sections 160, 162 164 focuses and accelerates the liquid, which would otherwise exit the orifice 96 as a spray, to cause the liquid to be discharged in a stream. A tab 166 on the forward side of the door as shown in FIG. 8, may be gripped by a user to pivot the generator between the stream position shown in FIG. 8 and the spray position shown in FIG. 7.
The spray dispenser of the alternate embodiment is used much like the dispenser of the preferred embodiment. The nozzle 32 may be rotated with respect to the housing 30 to alternately permit and inhibit liquid to pass through the nozzle orifice 96. When the door 154 is in the spray position shown in FIG. 7, the liquid is dispensed as a spray because the liquid is swirled in the swirl chamber 58 before being dispensed through the nozzle orifice 96. However, when the door is in the stream position as shown in FIG. 8, the diverging flowstreams of the spray are directed along the centerline of the straight passage 158. Because of the decreasing diameters of the rearward, intermediate and forward sections 160, 162, 164 of the passage 158, the liquid accelerates as it passes through the passage to produce a generally cylindrical stream discharge pattern having a relatively high velocity.
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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A fluid dispenser is used to dispense a foaming liquid from a container either as a spray or as a foam. The dispenser comprises a housing attached to a container of the liquid, a nozzle connected to the housing, a passage extending from the container interior to the nozzle orifice, a pump positioned along the passage, a valve positioned along the passage, and a foam generator attached to the nozzle. The nozzle has an orifice through which the fluid substance is dispensed. The valve is configured for alternating movement between an open and a closed position. The foam generator is configured to move with respect to the nozzle between a foaming position and a non-foaming position and is located adjacent the nozzle orifice when in the foaming position and remote from the orifice when in the non-foaming position. Alternatively, the fluid dispenser is used to dispense a liquid from a container either as a spray or as a stream. The alternate fluid dispenser is similar to the foaming fluid dispenser except that the foam generator is replaced with a stream generator.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims benefit priority to provisional patent application No. 62/019,858, filed Jul. 1, 2014; this application also bears relation to application Ser. No. 14/182,600, filed Feb. 18, 2014, and provisional patent application No. 61/770,458, filed on Feb. 28, 2013; all of which are incorporated herein by reference in entirety.
BACKGROUND
Field
The innovations herein relate to a safety magazine, and more particularly, to a specialized follower and integrated/unitary magazine with such follower that prevent jams, i.e., when holding and feeding blank cartridges into the chamber of a firearm.
Description of Related Information
Firearms magazines have been developed for their intended caliber and cartridge length to be held in a specific arrangement and presented to the firearm chamber through various firearm receiver actions. Further, blank cartridges, which are a type of cartridge for a firearm that contains gunpowder but no bullet or shot, are commonly used for simulation in training (such as military or police training), signaling, or theatrical/movie special effects wherein a sound or flash is needed but a projectile would not be safe. In a military application, soldiers typically train using the same rifle magazine for firing live cartridges (such as in firing ranges) as they do for blank ammunition (such as in urban training) This dual usage results in two debilitating outcomes for military personnel.
First, during training exercises, the blank ammunition often “jams” causing the service rifle to malfunction. Unfortunately, this jamming is virtually inevitable when using the same rifle magazine for firing live cartridges as for blank ammunition as the standard-issue magazine was never designed to fire blank ammunition. As everyone in uniform knows, the much shorter blank ammunition cartridges simply do not feed properly from the standard magazine into the service rifle. As a result, realism is sacrificed and valuable training time is lost.
Second, dual usage eventually results in the unfortunate situation wherein live cartridges may become mixed with blank cartridges, thereby seriously hurting or killing soldiers or anyone else in the vicinity.
Currently, there are no magazines that accept only blank cartridges and prevent live cartridges from being loaded into the magazine, thereby preventing the aforementioned pitfalls of current firearm magazines.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the disclosure. The disclosure may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:
FIG. 1 illustrates an exploded view of the blank cartridge magazine and its internal components consistent with one or more aspects of the innovations herein.
FIG. 2 illustrates a perspective view of the internal components of the blank cartridge magazine, as assembled, consistent with one or more aspects of the innovations herein.
FIG. 3 illustrates a front view of the blank cartridge magazine, as assembled, consistent with one or more aspects of the innovations herein.
FIG. 4 illustrates an underside perspective view of a cartridge follower and spring of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 5 illustrates a perspective view of the cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 6 illustrates a top view of the cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 7 illustrates a side view of the cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 8 illustrates a rear view of the cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 9 illustrates a cross-sectional side view of the blank cartridge magazine, as assembled consistent with one or more aspects of the innovations herein.
FIG. 10 illustrates a close-up section side view of the upper area of the blank cartridge magazine, as assembled consistent with one or more aspects of the innovations herein.
FIG. 11 illustrates a perspective top view of the blank cartridge magazine, showing loaded blank cartridges and prevented loading of a live cartridge consistent with one or more aspects of the innovations herein.
FIG. 12 illustrates a top view of the blank cartridge magazine, showing loaded blank cartridges and prevented loading of a live cartridge consistent with one or more aspects of the innovations herein.
FIG. 13 illustrates a side view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 14 illustrates a top view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 15 illustrates a front or rear view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 16 illustrates a perspective view of a slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 17 illustrates a front view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 18 illustrates a top view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 19 illustrates a side view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 20 illustrates an exploded view of the blank cartridge magazine and its internal components consistent with one or more aspects of the innovations herein.
FIG. 21 illustrates another perspective view of the internal components of the blank cartridge magazine, as assembled, consistent with one or more aspects of the innovations herein.
FIG. 22 illustrates yet another perspective view of the internal components of the blank cartridge magazine, as assembled, consistent with one or more aspects of the innovations herein.
FIG. 23 illustrates a top view of the cartridge follower in another embodiment consistent with one or more aspects of the innovations herein.
FIG. 24 illustrates a side view of cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 25 illustrates a rear view of the cartridge follower consistent with one or more aspects of the innovations herein.
FIG. 26 illustrates a side view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 27 illustrates a top view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 28 illustrates a front or rear view of a housing of the blank cartridge magazine consistent with one or more aspects of the innovations herein.
FIG. 29 illustrates a perspective view of a slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 30 illustrates a front view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 31 illustrates a top view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 32 illustrates a side view of the slide spacer insert consistent with one or more aspects of the innovations herein.
FIG. 33 illustrates different views of the magazine consistent with one or more aspects of the innovations herein.
FIG. 34A-H illustrates views of the follower cartridge consistent with one or more aspects of the innovations herein.
FIG. 35A illustrates a view of the slide insert consistent with one or more aspects of the innovations herein.
FIG. 35B illustrates another view of the slide insert consistent with one or more aspects of the innovations herein.
DETAILED DESCRIPTION
In the Summary of the Invention above and in the Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally. The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also one or more other components. Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).
The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example “at least 1” means 1 or more than 1. The term “at most” followed by a number is used herein to denote the end of a range ending with that number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%. When, in this specification, a range is given as “(a first number) to (a second number)” or “(a first number)-(a second number),” this means a range whose lower limit is the first number and whose upper limit is the second number. For example, 25 to 100 mm means a range whose lower limit is 25 mm, and whose upper limit is 100 mm.
The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the invention and illustrate the best mode of practicing the invention. In addition, the invention does not require that all the advantageous features and all the advantages need to be incorporated into every embodiment of the invention. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the invention and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
Overview
The present document addresses the aforementioned deficiencies of current magazines by disclosing a blank cartridge magazine that prevents live ammunition or cartridges from being loaded into the magazine and a specialized follower that prevents the ammunition from jamming.
Disclosed here are innovative, M16/M4 5.56 training magazine specifically designed to fire blank ammunition. Our blank-fire magazines feed blanks into the service rifle seamlessly without causing jams. And, our blank-fire magazine requires absolutely no modifications to the rifle and costs the same as a regular magazine. Perhaps most importantly, the blank-fire magazine makes training safer because it is simply impossible to load live rounds into our magazine.
In order to prevent the loading of only blank cartridges, and not live cartridges with projectiles, the systems here embody a standard sized magazine, for whichever kind of firearm is used, and prevent the loading of live ammunition while also aiding in the prevention of jams, where a round is stuck in the magazine and is unable to properly load into the receiver group.
Currently, blank cartridges are differentiated from live cartridge in that they have a shorter length because they do not have a projectile or bullet at their head end, but rather comprised of a casing having gunpowder and a primer and wherein the head end area is crimped.
EXAMPLES
FIGS. 1-10 illustrate an example embodiment of the blank cartridge magazine. FIG. 1 illustrates an exploded view of the embodiment of the magazine 100 for blank rifle cartridge or ammunition. The magazine comprises a housing 200 having a front wall 200 a and rear wall 200 b and right side wall 200 c and left side wall 200 d . Housing 200 further include an end or floor plate 210 [label] attached thereto which receives a distal end of a follower spring 130 . The floor plate 210 encloses the lower end of housing 200 to define, along with the side walls and front and back walls, an interior space sufficient to retain any desired number of cartridges 140 . The magazine further receives within its housing 200 a cartridge follower 110 for holding blank ammunition or blank cartridges 140 and for guiding them upwards through the housing 200 after rounds are ejected from the magazine into the firearm receiver group. A proximal end of biased spring 130 further attaches to the bottom surface of follower 110 . The magazine further receives slide insert 120 within its interior that is positioned adjacent the front wall 200 a , as further shown in FIG. 5-6 . In certain example embodiments as will be discussed below, the slide insert 120 may be removable, attached to the front wall 200 a or side walls 200 c 200 d by any example adhesion including but not limited to weld, rivet, glue, and/or friction. In certain examples of the invention, the magazine front wall has a thickness greater than that of the rear wall. The thickness of the front wall is fixed and formed integral with the front wall and is not removable and is not a sliding member that may be interchanged. Instead, the thickness of the front wall may be increased, for example, by welding and/or riveting or by any other means to permanently attach a structural element to the front wall to increase the thickness of the front wall, or by using a thicker material to make the thicker wall. The front wall having a thickness greater than that of a rear wall where the thickness of the front wall does not change increases the safety of the magazine in that the user is assured that the magazine is physically incapable of accepting live ammunition. A front wall that is not fixed and increased/decreased in thickness by one or more slideable/replaceable members may allow loading of live ammunition when the slideable/replaceable member is inadvertently removed from the magazine. However, a front wall having a fixed, permanent thickness in that the front wall may not be disassembled or manipulated to change the thickness of the front wall increases the reliability and effectiveness of the magazine. In this manner, non-projectile ammunition, such as blank ammunition, can be loaded while live projectile ammunition including the ball/projectile/bullet are prevented from loading.
Still referring to FIG. 1 , housing 200 can be may be made of any suitable material metal, titanium, aluminum, steel, or polymer. Further, housing 200 may be integrally formed from sheet metal and folded into the final configuration as shown. The distance between the housing 200 front wall 200 a and rear wall 200 b may correspond generally to and be slightly greater than the length of the blank cartridges 140 to be stored. It should be noted that the dimensions of the magazine housing 200 and the cartridges to be loaded into the housing 200 could vary depending on the caliber of round and type of firearm it is intended to be used with. The examples in this description generally use the dimensions of a standard M-16 using a 5.56 mm caliber round. However, the general descriptions and embodiments described here could be adopted to any kind of magazine, used in any type of firearm, including hand guns, as well as rifles and long barreled firearms.
It is contemplated within the scope of the invention that the internal components of the magazine 100 , such as follower 110 , slide insert 120 , and spring 130 can either be manufactured and assembled with housing 200 and the housing or any of the aforementioned components can be color coded, labeled, or have indicia indicating that the magazine is for blank ammunition. Alternatively, follower 110 , slide insert 120 , and spring 130 can be retrofitted with existing magazine housings of rifles that fire live ammunition. Specifically, the internal components of a live ammunition magazine, such as an M16 or M4 rifle, can be replaced with the internal components of the present invention, such as follower 110 , slide insert 120 , and spring 130 . Further, the components of the present solution, such as the follower, slide insert, and spring can be insertable into a standard M16 style magazine well, wherein the safety magazine is adapted for enabling non-lethal training cartridges to be fired while preventing the loading and firing of standard 5.56×45 mm NATO cartridges.
FIG. 2 shows the spring 130 pushing the cartridge follower 110 up in the main body of the magazine housing 200 . The example in FIG. 2 also shows the blank cartridges loaded 140 . The slide insert 120 from FIG. 1 takes up the space where the projectile on a live round would extend past the cartridge jacket.
Referring now to FIG. 3 , showing a front on view of the magazine, loaded with blank rounds 140 , a pair of feed lips 202 and 204 are positioned on the upper edges of the side walls to single feed the cartridges into receiver group (not pictured).
FIG. 4 shows an example of the cartridge follower 110 and the spring 130 without the magazine housing shown. The cartridge follower 110 may be made of a heat resistant molded polymer, metal, ceramic, or other suitable material. Further, spring 130 and floor plate 210 may have corresponding projections or recesses to locate an end of the spring at a desired location with respect to the housing floor.
Still referring to FIG. 4 , cartridge follower 110 has a main body plate 111 having a detent projection 118 underneath it for receiving a first end of spring 130 . Further, a first elongated projection or guide 114 extends downward from main body 111 of cartridge follower 110 , wherein the guide 114 can be attached to the main body 111 separately or formed integrally with main body 111 . Guide 114 assists the guiding of cartridge follower 110 within the magazine housing 200 as the cartridge follower 110 moves up and down in the magazine housing, depending on how many cartridge rounds are loaded in it. In the example embodiment, first guide 114 is position adjacent to the interior surface of rear wall 200 b , thereby allowing and guiding the follower along the length of the rear wall 200 b . However, it is contemplated within the scope of the invention that guide 114 can also be configured to be position adjacent to the interior of front wall 200 a of the magazine. Here, guide 114 is substantially perpendicular with respect to the top surface (surface contacting the cartridge) of main body 111 and is further reinforced by a pair of protrusions 110 a and 110 b that further assist the guiding of follower 110 within the walls of housing 200 when it is positioned in and moves up and down within the housing.
On the opposing side of cartridge follower 110 , is an elongated second protrusion or guide 112 , wherein second guide 112 can be attached separately to main body 111 or formed integrally with main body 111 of the cartridge follower 110 . Second guide 112 assists the guiding of follower 110 within housing 200 as explained above. In the example embodiment, second guide 112 is position adjacent to a slide insert 120 (from FIG. 1 ) that is positioned adjacent to the interior surface of front wall 200 a , thereby allowing and guiding the follower along the length of slide insert 120 and front wall 200 a . However, it is contemplated within the scope of the invention that guide 112 can also be configured to be position adjacent to the interior of rear wall 200 b of the magazine.
In the example of FIG. 4 , guide 112 is substantially perpendicular with respect to the top surface (surface contacting the blank cartridge) of main body 111 and is further reinforced by a block 110 c having opposing lobed protrusions that further assist the guiding of the follower 110 within the walls of housing 200 . In the example shown, second guide 112 is slightly longer in length as it extends into the magazine housing and away from the cartridge follower 110 than first guide 114 . Further, second guide 112 can also include an elongated recess or channel 112 a that can further engage an elongated projection or track in the magazine housing (not shown) along insert 120 in another embodiment of the invention, thereby assisting in positioning and movement within the magazine along slide insert 120 . Alternatively, in another embodiment, channel 112 a can also engage any track or elongated projection along the interior of the front or rear walls of the housing 200 .
FIGS. 5-8 illustrate the cartridge follower 110 in various orientations. FIG. 5 shows a top perspective with a blank cartridge mold 116 in the main body 111 of the cartridge follower 110 . The first guide 114 and second guide 112 are also shown.
FIG. 6 shows a detail top down view embodiment of the blank cartridge mold 116 in the cartridge follower 110 . In this detail, the blank cartridge has various bulges 116 a 116 b 116 c running the length of the blank cartridge mold body 116 . The front includes a ridge 116 d that mimics a projectile and follows the contour of a cartridge front section. The rear 116 e includes a tapered section. Here, grooves 116 a and 116 b can be concave or convex in configuration. In addition, mold 116 has a peak area or ridge 116 c . It is contemplated within the scope of the invention that mold 116 can be situated on side on the top surface of the main body 111 . Further, it is contemplated within the scope of the invention that mold 116 can be integrated with the main body of follower 110 or can be separately be affixed to or attached to the main body 111 . Also, it is contemplated within the scope of the invention that the cartridge mold can be of any length, configuration, shape, or dimension.
FIG. 7 shows the main body 111 of cartridge follower 110 with a front end 111 a , rear end 111 b . FIG. 7 also shows the first guide 114 and second guide 112 extending form the cartridge follower main plate body 111 .
FIG. 8 shows the cartridge follower 110 with a right side end 111 c , and left side end 111 d . Further, main body 111 includes a projected blank cartridge mold 116 . Here, the blank cartridge mold 116 is approximately one-half of a simulated blank cartridge and having similar dimensions of a blank cartridge. This blank cartridge mold 116 mimics a cartridge when the other cartridges are loaded into the magazine and the cartridge follower is depressed into the magazine.
Cartridge mold 116 allows a user to quickly see that the magazine is for a blank cartridge and not live cartridges prior to loading the magazine. In addition, mold 116 allows the stack of cartridges 140 to be slightly offset from each other when stacked within the housing, thereby allowing each individual cartridge to be fed through the feed lips and further prevent jamming of the firearm.
FIGS. 9 and 10 show detail cut away views of the cartridge housing 200 . FIG. 9 shows the front 200 a and rear 200 b walls of the housing 200 as well as the floor plate 210 . FIG. 10 shows a close up detail of the top of the magazine housing 200 where the cartridges are fed into the firearm receiver group (not shown). The cartridge 140 is shown with a cartridge body 144 and a narrower front 142 where a projectile would protrude if there was one as in a live round. But instead, in this example, a slide insert 120 is shown in the magazine housing 200 which restricts loading cartridges that have projectiles 150 . FIG. 10 also shows details of a front guide 112 , channel 112 a , second guide 114 and second channel 114 a that may position the cartridge follower as it rides up and down within the magazine housing.
FIGS. 11-12 illustrate an embodiment of the invention wherein a live ammunition cartridge 140 a is shown in the magazine which can only accommodate blanks. Thus, because the live round includes a projectile end, the slide insert 120 prevents the live round from being inserted into the housing 200 .
FIGS. 13-15 illustrate an example embodiment for a magazine housing 200 holding the blank cartridges of the present solution. In particular, a range and preferred measurements for the housing will now be described with references to numerals [insert figs with the following numbering into drawing set] A1-A3, B1-B6, and C1-C5, wherein the measurements/dimensions can be approximations (approx.) and referred to herein in inches (in. or in). Here, A1 can be approx. 1 in., preferably 1.12. A2 can be approx. 7 in., preferably 7.06 in. A3 can be approx. 2-3 in., preferably 2.52 in. B1 can be approx. 0.5-1 in., preferably 0.87 in. B2 can be approx. 0.5 in., preferably 0.58 in. B3 can be approx. 3 in., preferably 3.29 in. B4 can be approx. 3 in., preferably 3.47 in., B5 can be approx. 0.1 in., preferably 0.14 in. B6 can be approx. 0.4-0.6 in., preferably 0.50 in. C1 can be approx. 6 in., preferably 6.75 in. C2 can be approx. 6 in., preferably 6.45 in. C3 can be approx. 0.3-0.5 in., preferably 0.41 in. C4 can be approx. 0.3-0.4 in., preferably 0.50 in. C5 can be approx. 0.1-0.3 in., preferably 0.19 in. C6 can be approx. 0.1-0.3 in., preferably 0.21 in.
FIGS. 16-19 show perspective angles of the slide insert 120 . The slide insert is contoured to follow the front wall of the magazine housing 200 a . In various embodiments, the slide insert would be configured to slide into a magazine of whichever caliber and prevent a live round from being inserted.
FIGS. 20-23 and 26-32 are more illustrations of perspective views of the internal components of the blank cartridge magazine, as assembled, consistent with one or more aspects of the innovations herein.
FIGS. 23-25 illustrate an example embodiment for a follower of the present solution. In particular, a range and preferred measurements for the housing will now be described with references to numerals D1-D12, E1-E11, and F1-F6, wherein the measurements/dimensions can be approximations (approx.) and referred to herein in inches (in. or in). Here, D1 can be approx. 0.1-0.3 in., preferably 0.20 in. D2 can be approx. R0.1-R0.3 in., preferably R0.17 in. D3 can be approx. 0.1-0.4 in., preferably 0.25 in. D4 can be approx. 0.1-0.4 in., preferably 0.24 in. D5 can be approx. R0.1-R0.3 in., preferably R0.17 in. D6 can be approx. 0.2-0.4 in., preferably 0.33 in. D7 can be approx. 1-3 in., preferably 1.47 in. D8 can be approx. 1-3 in., preferably 1.27 in. D9 can be approx. 0.2-0.4 in., preferably 0.22 in. D10 can be approx. 0.2-0.4 in., preferably 0.32 in. D11 can be approx. 0.4-0.8 in., preferably 0.67 in. D12 can be approx. 0.1-0.3 in., preferably 0.18 in. E1 can be approx. 1-3 in., preferably 2.15 in. E2 can be approx. 0.5-4 in., preferably 1.24 in. E3 can be approx. 0.1-4 in., preferably 0.94 in. E4 can be approx. 0.05-0.3 in., preferably 0.14 in. E5 can be approx. 1-4 in., preferably 1.82 in. E6 can be approx. 0.05-0.3 in., preferably 0.17 in. E7 can be approx. 0.05 in-0.3 in., preferably 0.16 in. E8 can be approx. 0.1-0.5 in., preferably 0.35 in. E9 can be approx. 0.05-0.3 in., preferably 0.18 in. E10 can be approx. 0.1-4 in., preferably 0.66 in. E11 can be approx. 0.005-0.5 in., preferably 0.09 in. F1 can be approx. 0.2-1.5 in., preferably 0.76 in. F2 can be approx. 0.1-0.7 in., preferably 0.32 in. F3 can be approx. 0.1-0.4 in., preferably 0.22 in. F4 can be approx. 0.1-1.0 in., preferably 0.49 in. F5 can be approx. 0.1-4 in., preferably 1.24 in. F6 can be approx. 0.1-4 in., preferably 1.42 in.
FIGS. 33-37 illustrate an example additional or alternative embodiment of the invention of the firearm magazine.
FIG. 33 illustrates an implementation of the invention of the firearm magazine. In particular, measurements will now be described with references to numerals K1-K15, wherein the measurements/dimensions can be approximations (approx.) and referred to herein in inches (in. or in). Here, K1 can be approximately can be approx. 1-10 in., preferably 7.11 in. K2 can be approximately 0.01-3 in., and preferably 1.06 in. K3 can be approximately 0.01-3 in., and preferably approximately 0.60 in. K4 can be approximately 0.01-3 in., and preferably approximately 0.27 in. K5 can be approximately 0.01-1 in., and preferably approximately 0.19 in. K6 can be approximately 0.5-5 in., and preferably approximately 2.10 in. K7 can be approximately 0.5-5 in., and preferably approximately 1.96 in. K8 can be approximately 0.01-3 in., and preferably approximately 0.25 in. K9 can be approximately 0.06 in. K10 can be approximately 0.01-3 in., and preferably approximately 0.94 in. K11 can be approximately 0.1-10 in., and preferably approximately 5.99 in. K12 can be approximately 0.5-6 in., and preferably approximately 2.53 in. K13 can be approximately 0.25-3 in., and preferably approximately 0.88 in. K14 can be approximately 0.25-3 in., and preferably approximately 0.76 in. K15 can be approximately 0.1-3 in., and preferably approximately 0.50 in.
FIGS. 34A-H illustrate an embodiment of the follower cartridge and its components from various perspectives.
FIG. 34A illustrates a top down view of an example cartridge follower 3110 which has a different configuration than those described above. It should be noted that any of various embodiments of cartridge followers including combinations of the various examples described may be used.
In the example of FIG. 34A , the word “SAFE” is etched or molded into the cartridge follower. This is to allow the user to see that the magazine is only intended and can only hold blank rounds and not live rounds.
In the example of FIG. 34A , on one end of the cartridge follower, the first guide 3114 which extends from the back end 3111 b is shown approximately 0.31-0.33 inches in width, preferably 0.32 inches measured from side 3111 c to side 3111 d of the guide.
The second guide 3112 includes lobes 3110 c , 3100 d which extend outwardly from the cartridge follower body 3110 . The lobes 3110 c , 3100 d are shown completing a 75-85 degree, preferable 79 degree arc. Between the two lobes 3110 c , 3110 d is a semicircular cutout 3220 .
The width across the cartridge follower 3110 main body at the narrowest point can be approx. 0.57-0.59 inches in some examples, preferably 0.58 in. There are approx. 0.17-0.23 in., preferably 0.2 in. of space 3407 between front end 3111 a and slide insert 3120 .
FIG. 34B illustrates a cutaway view from A-A as shown in FIG. 34A . In certain examples, the radius of the body of the blank cartridge mold 3116 can be approx. 0.17-0.23 in., preferably 0.2 in. high.
FIG. 34C illustrates a partial cutaway view from B-B as shown in FIG. 34A , focusing on the and center appendage 3220 . The downwardly extending sides of the center appendage 3220 each angle inwards approximately 4 degrees. The fillets where the center appendage 3220 meets the bottom of the main cartridge follower body 3111 can be approx. 0.01-0.03 in. each, preferably 0.02 in. The fillets where cartridge follower body 3111 meets the second guide 3112 are all approx. R0.01-R0.03 in., preferably R0.02 in.
FIG. 34D illustrates a cutaway view from C-C as shown in FIG. 34A , including the cartridge mold 3116 , second guide 3112 , channel 3112 a , first guide 3114 , the center appendage 3220 . In this example, the second guide is shown at an angle between 90 and 96 degrees, preferably, 93 degrees extending from the cartridge follower 3110 . Thus, the guides can fit into a curved magazine and slide within it. Second guide 3112 can extend approx. 0.67-0.73 in., preferably 0.7 in. from the cartridge follower 100 . In certain embodiments the bottom fillets where channel 3112 a and guide 3112 meet can be approx. R0.01-R0.03 in., preferably R0.02 in. The farthest edges of channel 3112 a and guide 3112 angle inward at approximately 5 degrees. The edges of 3112 also angle inwards at approximately 5 degrees. The fillets where the bottom of 3111 and 3112 meet can be approx. R0.01-R0.03 in., preferably R0.02 in. The fillets where the bottom of 3111 and top of meet can be approx. R0.01-R0.03 in., preferably R0.02 in. The center appendage 3220 can be approx. 1.17-1.23 in., preferably 1.2 in. long. The width of the center appendage 3220 where it meets the cartridge follower body 3111 can be approx. 0.27-0.33 in. in certain examples, preferably 0.3 in. Guide blocks 3110 a and 3110 b can extend approx. 0.07-0.13 in., preferably 0.01 in. from cartridge follower body 3111 . The edges of first guide 3114 angle inwards at approximately 4 degrees. First guide 3114 can extend downwards approx. 0.77, preferably 0.8 in. The distance between the bottom of cartridge follower body 3111 and the top side 3111 b can be approx. 0.07-0.13 in. apart in certain embodiments, preferably 0.1 in. The blank cartridge mold 3116 front end 3116 a can have a slope of approximately 13 degrees.
Still referring to FIG. 34D , the thickness of the cartridge follower body 3111 can be approx. 0.07-0.13 in., preferably 0.1 in. The cartridge follower body 3111 may also include a thickness step which increases the thickness at the second guide 3114 end to approximately 0.2 inches. Thus, the example of FIG. 34A shows a stepped thickness of the cartridge follower body 3111 with one end being approximately twice as thick as the other end, and step near the blank cartridge mold 3116 tapered section 3117 .
The length of the cartridge follower from side 3111 b excluding second guide 3112 to the center of the center appendage 3220 can be approx. 1.07-1.13 in., preferably 1.1 in. The measurement from the bottom to the top of side 3111 a can be approx. 0.07-0.13 in., preferably 0.1 in. The outer curve of the blank cartridge mold 3116 can be approx. R0.07-0.09 in., preferably 0.08 in.
FIG. 34E illustrates an example bottom view of the cartridge follower 3110 . As shown in the example, the overall length of the cartridge follower can be approx. 2.07-2.13 in., preferably 2.1 in. long. The overall length of the cartridge follower will of course depend on the dimensions of the slide 3120 which can be used to restrict the loading of live rounds into the magazine, depending on the firearm and caliber round it is intended to be used with. In the example of FIG. 34E the distance of the cartridge follower 3110 without the first guide 3112 can be approx. 1.97-2.03 in., preferably 2.0 in.
In certain examples, a center appendage 3220 is shown extending outwardly from the cartridge follower 3110 . The cartridge follower 3110 has a back side with a second guide 3112 to fit into the magazine. In the example shown in FIG. 34E , the back side 3110 a extends outwardly and is approximately 0.14 to 0.34 in. and preferably 0.24 in. deep. This dimension includes the second guide 3112 which in this example widens into a larger rear guide 3110 b . In certain examples the dimensions of 3110 a the second guide 3112 can be can be approx. 0.9-0.11 in., preferably 0.1 in. and the body of the rear guide 0.12 to 0.16 in. and preferably 0.14 in. deep. The sides of the rear guide 3110 b which extend beyond the second guide 3112 may be between 0.18 and 0.22 in. preferably 0.2 in. wide on either side of the second guide 3112 .
Still referring to FIG. 34E , the example shows the rear guide 3110 b having a semicircular cutout with a radius of approx. R0.27-R0.33 in., preferably R0.3 in. wide. Also shown is a cutout flange near the front of the cartridge follower and the front guide 3110 c , 3110 d . This front guide in the example extends outwardly from the cartridge follower in the same way the rear guide 3110 a , 3110 b and the center appendage 3220 . Further, the front end of the cartridge follower includes cutouts on either side. The example shows dimensions of between 28 and 36 degrees, preferably is 32 degrees. Also shown in the example is the front guide 3110 c , 3110 d with a semicircular cutout similar to the one on the rear guide. The semicircular cutout in the front guide is cut from both sides of the front guide making a roughly hourglass shape in the example.
FIG. 34F illustrates a cutaway view from F-F as shown in FIG. 34B , focusing on channel 3112 a and the part of the center appendage 3220 that extends below it. The inner grooves of channel 3112 a angle inwards 3 degrees. The outer grooves of channel 3112 a angle inwards 2 degrees.
FIG. 34G illustrates a cutaway view from G-G as shown in FIG. 34B from the opposite perspective illustrated in FIG. 34F , focusing on short guide 3114 and the part of the center appendage 3220 that extends below it. The inner grooves on second guide 3114 angle inward 5 degrees. The distance between the outer and inner grooves can be approx. R0.17-R0.23 in. in some examples, preferably R0.2 in. The inner radius of the blank cartridge mold 3116 can be approx. R0.17-R0.23 in., preferably R0.2 in.
FIG. 34H illustrates a cutaway view from H-H as shown in FIG. 34A , bisecting the center appendage 3220 . The base 3220 of the center appendage 3220 can be approx. 0.17-0.23 in., preferably 0.2 in. The sides of followed upwards angle outward 4 degrees. In some examples, the base 3220 and the bottom of cartridge follower 3111 can be approx. 0.07-0.13 in. apart, preferably 0.1 in. The fillets where the blank cartridge mold 3116 meets cartridge follower body 3111 can be approx. R0.01-R0.03 in., preferably R.02 in.
FIG. 35A illustrates an example top view of slide insert 3120 . Slide insert 3120 has a length of approx. 5.97-6.03 in., preferably 6.0 in., a width of approx. 0.47-0.53 in., preferably 0.5 in., and a depth of approx. 0.17-0.23 in., preferably 0.2 in. Located approx. 0.47-0.53 in., preferably 0.5 in., from the top and bottom of slide insert 3120 are the centers of circular openings 3502 a and 3502 b . Circular openings 3502 a and 3502 b are both positioned approx. 0.27-0.33 in., preferably 0.3 in., from the left side of slide insert 3120 . The distance from the center of circular opening 3502 a to the center of circular opening 3502 b can be approx. 5.17-5.23 in., preferably 5.2 in. Circular openings 3502 a and 3502 b are both comprised of two circular openings with diameters of approx. 0.126-0.136 in., preferably 0.131 in., within a counter bore where a larger hole with a diameter approx. 0.220-0.230 in., preferably 0.225 in., has a depth of approx. 0.126-0.136 in., preferably 0.131 in.
FIG. 35B illustrates an example side view of slide insert 3120 . The radius of the curve just below the center of slide insert 3120 can be approx. 9.17-9.23 in., preferably 9.2 in. The angle between the planes extending from the top and bottom of slide insert 3120 to the place of curvature is approximately 164 degrees or whatever is necessary to fit into the appropriate magazine.
From the foregoing it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense.
While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts described herein, except insofar as such limitations are included in the following claims. For example, it is contemplated within the scope of the invention that the cover and its legs may be attached to the frame or metal frame of the shopping cart and not the basket. Or alternatively, the cover and legs being attached to both the frame and basket. Further, it will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations.
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Systems and methods herein relate to a safety magazine for blank ammunition or “blanks”. In one illustrative implementation, a specially-shaped follower is utilized to engage and advance the blank ammunition without jamming, i.e., when holding and feeding blank cartridges into the chamber of a firearm. In other implementations, integrated/unitary magazines including such a follower are disclosed, which also prevent jams otherwise common in the field of magazines converted to handle blank rounds of ammunition. According to such implementations, live ammunition or cartridges are prevented from being loaded into the magazine and a specialized follower that prevents the ammunition from jamming is provided.
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DESCRIPTION OF THE DRAWINGS
The present description will be better understood from the following detailed description read in light of the accompanying drawings, wherein:
FIG. 1 Illustrates a conventional Advanced Streaming Format (“ASF”) data file structure and its use.
FIG. 2 is a block diagram showing a first example of a table of contents (“TOC”) Object inserted as a new top-level object to form an ASF file with a TOC.
FIG. 3 is a block diagram showing a second example of a TOC Object inserted as a new extended header object to form an ASF file with a.
FIG. 4 is a block diagram showing the layout of the TOC Object that tends to provide effective browsing of media content.
FIG. 5 is a table illustrating an example of data fields that may be used in an ASF TOC.
FIG. 6 is a table illustrating an example of the sub data fields that may be contained in an ASF table of contents field.
FIG. 7 is a table illustrating an example of the representation of the structure of the entry lists sub data fields that may be contained in an ASF table of contents field.
FIG. 8 is a table illustrating an example of possible contents of the entries sub field.
FIG. 9 illustrates an exemplary computing environment in which the systems and methods described in this application, may be implemented.
Like reference numerals are used to designate like parts in the accompanying drawings.
DETAILED DESCRIPTION
The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or utilized. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.
Although the present examples are described and illustrated herein as being implemented in an ASF media file system, the system described is provided as an example and not a limitation. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of media file systems, including AVI and the like.
Most books contain a table of contents which gives the reader a hierarchical overview of the book contents and helps the reader to navigate through the pages quickly. Many books may also have a semantic index table to allow reverse lookup of the page numbers which are related to certain pre-selected keywords.
In contrast, most existing multimedia files such as WMV files do not have such index information. To find an interesting scene in a WMV file, the user would typically have to manually browse through the entire file. Such task is often tedious and time consuming especially for large files. Therefore, the examples described below seek to add advanced indexing functionality to multimedia files.
There are several unique aspects of the ASF specification that are addressed with the ASF Table of Contents (“TOC”) object. The ASF specification may require any new top level objects to be inserted between the Data Object and the Index Object(s). A typical user defined index object, or objects, would be appended at the end of an ASF file. However appending an object to the end of a file may not work with all parsers or on all PCs or other multimedia devices. Next, in a conventional user defined index object hierarchical indices are typically not supported; and finally per-entry metadata typically allowed in a user defined object typically has the same fixed size. These typical limitations tend to be addressed by the new TOC Object.
The TOC object is typically comprehensive in that it may enable a hierarchical TOC and semantic indices in ASF files for a broad class of digital media applications for audio applications, video applications and the like. The ASF files including a TOC object are typically compatible with, and should work on, all devices capable of processing an ASF media file. The ASF file having a TOC object may allow new metadata of arbitrary type and size to be added without modification of the current design. The ASF file having a TOC object may provide search capability that may enable content-based indexing and retrieval for ASF files. And the ASF file having a TOC object may provide interoperability by creating and sharing the same indexing capability in different media applications, and on different platforms.
The examples introduce a table of contents structure to enable hierarchical table of contents and semantic indices in ASF files. The structure is typically simple but extensible. It typically allows fast read and write operations, and typically supports arbitrary levels of hierarchy to ensure maximum flexibility. Each entry in the structure can also contain any type of metadata to allow future extension and support a wide range of applications.
FIG. 1 Illustrates a conventional Advanced Streaming Format (“ASF”) data file structure and its use. A conventional ASF media file 100 may be stored on a computer 101 , and played 105 by, a conventional media player application 103 or the like. Those skilled in the art will realize that an AVI media file or its equivalent may be substituted for the ASF media file 100 . Current ASF media files 100 typically do not provide a table of contents structure that is sufficient. Media players 103 typically reside on a processor based device such as the computer 101 shown. Those skilled in the art will realize that media players may be utilized by other devices such as consumer electronics devices and the like. Typically the ASF file is loaded by an application 103 , and subsequently processed (or played) by the application 103 , to produce an output such as the video output 109 and, sound output 107 shown here. ASF files 100 can convey a variety of information such as music, video and the like. Media players may include audio players, video players, editing programs, digital photo albums, and the like. The possible outputs 107 , may include audio video and the like.
A typical ASF file may include a header object 102 , a data object 104 , and one or more index objects 108 110 . In the ASF file structure space is provided for other top level objects 106 . An ASF header object 102 typically includes a set of tables that may include information on the entire file, including the size of the file, if the file is packetized, how large the packets are, if there is audio stream, the number of streams present in the file, and the like. An ASF data object 104 may include the data or media content.
The ASF index 110 is typically a set of markers that may be coupled to the various points in the data object 104 . This typically allows the media player application to seek those marked points quickly. The following paragraphs describe examples of ASF files that have an added TOC object. An ASF file may be provided with one or more TOCs at various locations within the file structure.
FIG. 2 is a block diagram showing a first example of a table of contents (“TOC”) object 202 inserted as a new top level object to form an ASF file with a TOC 200 . In this example the TOC object 202 has been disposed between the data object 104 , and the index object 108 as a high level data object. The header object 102 , and the index object are as previously described and conventionally constructed. This TOC object location may be useful in video editing applications where the TOC is created after the media is recorded or processed. For example it may be unproductive to place the TOC at the front of the ASF file because the size and content are not known until the recording or editing are completed. If insufficient space were reserved when keeping the TOC up front a time and storage space expensive data move operation would typically be needed to make room for the final TOC. By putting the TOC at the end the TOC is simply appended to the ASF media file when processing is completed.
The TOC object 202 may allow increased functionality with media player applications by allowing search and indexing to be incorporated into the application's designs to utilize the information contained in the TOC object, without appreciably increasing the compressed media file's size. The TOC object may be uncompressed, and contains all of the information it needs to produce a table of contents.
The TOC is typically an ASF object which can be placed either between the Data Object 104 and the Index Object(s) 108 , 110 , as a new top level object or inside the Header Extension Object in an ASF file as a new extended header object. There can also be multiple instances of the TOC Object in an ASF file, e.g., one that mimics the table of contents typically found in the front of a book; one that mimics the Indices typically found in the end of a book; one per media stream, etc.
The TOC Object and CDD Descriptors typically comply with the ASF formatting guidelines. In particular, typically all structures have one byte packing, typically all references to Unicode strings imply a null-terminated string, and objects and structures are typically stored in little-endian order.
The basic data types utilized may include BYTE, WCHAR, WORD, DWORD, QWORD, and GUID. BYTE data type typically has a size of 8 bits and is not signed. WCHAR data type typically has a size of 16 bits and is not signed. WORD data type typically has a size of 16 bits and is not signed. DWORD data type typically has a size of 32 bits and is not signed. QWORD data type typically has a size of 64 bits and is not signed. GUID data type typically has a size of 128 bits and is not signed.
The Table of Contents (TOC) Object 202 is a new ASF object for storing advanced index information and associated metadata in ASF files. Examples of such index information include table of contents, semantic indices and story boards. Examples of the associated metadata include entry-based textual description, cover arts, thumbnails, audiovisual DSP properties, cross references and the like.
Most existing multimedia files do not contain an index. To find an interesting scene, typically the user will browse the file manually. The examples provided describe a solution for adding advanced index functionality to multimedia files. It typically extends the User-Defined-Index (UDI) Object design of the Advanced Streaming Format (ASF) specification to create a new indexing object which complies with ASF formatting guidelines. This new indexing object is called a table of contents object (“TOC Object”).
The TOC Object is an extensible structure which allows a hierarchical table-of-contents, semantic indices and associated metadata to be stored in ASF files. Unlike a standard UDI object, this new TOC Object may be inserted into the ASF file as either a top-level or extended header object. The result is a format which is compatible with most devices and interoperable such that the indexing capability may be shared with many different media applications and platforms.
FIG. 3 is a block diagram showing a second example of a TOC Object 202 inserted as a new extended header object 301 to form an ASF file with a TOC. In the example shown the TOC object 202 is disposed as an extension of the ASF header 102 . This configuration may be useful where the entire file is not streamed before playback. By putting the TOC object at the beginning of the file the TOC may be displayed before the entire file is downloaded. With this method the user may download the TOC and then pick which portions of the media file to download without having to download the entire file.
FIG. 4 is a block diagram showing the layout 400 of the TOC Object 202 that tends to provide effective browsing of media content. In the TOC object an TOC Header 408 is first provided that identifies the TOC object 202 and describes its overall properties.
The TOC header 408 is followed by a number of hierarchal entry lists contained in the TOC Data section 411 . The TOC Data section 411 contains the TOC information that starts with an Entry List “level 0 ” 412 shown in the inset. Each Entry List is basically a group of entries that could correspond to the chapters of a video. As shown in the inset each level in an Entry List corresponding to chapters 412 may in turn have its own Entry List that could correspond to sections within a chapter 413 . Accordingly each section may have its own Entry List that could form subsections of the section 414 . This nested structure may be repeated without limit, and is shown to the right of TOC Headder 408 and TOC data 411 . Physically each Entry List makes up a level in the TOC Object, as shown in the inset. The portion of the diagram to the right of TOC header 408 , and TOC Data 411 illustrates the heiarchal relationship amoung the Level Entry Lists. For example the level 0 entry list of chapters may be the first entry list to follow the header. The level 1 entry list that lists the chapters may follow the entry level 0 list. The entry level 2 list that lists the sections may follow the level 1 entry list. The entry level list 3 that lists the sub sections may follow the entry level 2 list, and so on. Each entry may contain a description data field 410 that may be used to store metadata.
FIG. 5 is a table illustrating an example of data fields 402 , 404 , 406 that may be used in an ASF TOC 202 . The object ID field 402 specifies the GUID for the table of contents object. The value of this field shall be set to 35003B7B-A104-4c33-A9EE-E2A240431F9B. The object size field 404 specifies the size, in bytes, of the Table of Contents Object. Valid values for the example shown are at least 70 bytes. The final field shown is the example ASF table of contents field 406 . The ASF table of contents field 406 may contain a number of sub fields, or entry lists as previously described.
FIG. 6 is a table illustrating an example of the sub data fields that may be contained in an ASF Table of Contents field 406 . In the Table of Contents 406 the data fields included in the header include 602 , 604 , 606 , 608 , 610 , 612 , 614 , 616 , 618 . TOC data 411 is included in the entry lists 620 .
The ID 602 sub field may specify a unique identifier for the Table of Contents 406 . The stream number 604 sub field typically specifies the media stream number related to the table of contents. The Type 606 sub field typically specifies the type of the table of contents. It may be one of a number of the pre-defined GUIDs, or any other user-defined GUID. Examples of predefined GUIDs include ASF_TOC_Type_Playlist (ACC8DAA6-9D06-42d6-8704-2B2CA8E1FD9A), ASF_TOC_Type_Editlist (2F133F06-0701-49f9-AD38-602F00A7882D), ASF_TOC_Type_User_Bookmarks (7A0D993C-C1B0-473b-A048-2AODE74E93A5), ASF_TOC_Type_DSP_Metadata (1AEDA271-281D-43ac-8735-8911D408FBCD), and the like. The Language ID index 608 sub field typically specifies the language, if any, which this table of contents uses or assumes. The Description Size 610 sub field typically specifies the size, in bytes, of the description 612 sub field. The Description 612 sub field typically contains a textual description of the Table of Contents. The Number of Entry Levels 614 sub field typically specifies the number of levels of the entry hierarchy. The Context Size 616 sub field typically specifies the size, in bytes, of the Context 618 sub field. The Context 618 sub field may contain any additional description data for this table of contents. Its size is typically determined by the Context size sub field 616 . The Entry Lists sub field 620 typically consists of X lists of Entries where X equals the Number of Entry Levels 614 .
FIG. 7 is a table illustrating an example of the representation of the structure of the Entry Lists 620 sub data fields that may be contained in an ASF Table of Contents field 506 . The Number of Entries 702 sub field typically specifies the number of entries existing in this list. The Entries 704 sub field includes a number of possible fields.
FIG. 8 is a table illustrating an example of possible contents of the Entries sub field 704 . The Entries 704 sub field typically consists of Y Entries where Y is equal to the Number of Entries 702 . The Entry Title Size 802 field typically specifies the size, in bytes, of the Entry Title field. The Entry Title 804 field typically specifies the title for this Entry. Its size is determined by the Entry Title Size. The Start Time 806 field typically specifies the start presentation time for this entry, in 100-nanosecond units. The End Time 808 field typically specifies the end presentation time for this entry, in 100-nanosecond units. The time is set to 0 if it is not specified. The Start Packet Offset 810 field typically specifies the byte offset from the start of the first Data Packet in the ASF file to the start of the first Data Packet of this Entry. Note that for video streams that contain both key frames and non-key frames, this field will correspond to the closest key frame prior to the time interval. The End Packet Offset 812 typically specifies the byte offset from the start of the first Data Packet in the ASF file to the start of the last Data Packet of this Entry. Set to 0 if not specified. The Representative Frame Time 814 typically specifies the presentation time of a representative frame for this Entry, in 100-nanosecond units. The Number of Sub-Entries 816 typically specifies the number of sub-entries (i.e., children) under this Entry. Set to 0 if this entry has no sub-entries. The Sub-Entry Indices 818 typically consists of Z Sub-Entry Indices where Z is equal to the number of Sub-Entries. Each Sub-Entry Index is a WORD and contains the position of the corresponding child Entry in the next level Entry List. The Description Data Size 820 typically specifies the size, in bytes, of the Description Data. Set to 0 if this Entry has no additional description data. The Description Data Type 822 typically specifies the type of the Description Data. When Description Data Size is 0, this field will not exist.
The Description Data 824 entry typically contains any additional description data about this Entry. Its size is determined by the Description Data Size. The Description Data must belong to a predefined Description Data Type. A Description Data Type may be defined by anyone at anytime as long as the authoring application and the targeted client applications share the type definition and all know how to parse the data. The description data field 824 typically allows scalability and extensibility of the TOC object 202 . Additional descriptive data that may be disposed here includes .jpg, .wav, .html, data, and the like. Examples of this additional data might include thumbnail pictures, sound clips and the like. The TOC may be added to at a later time as well. For example if a user repeatedly opens a media file to a specific chapter the application may make note of this fact and place a marker in the Description Data Field 824 , so that the application can open the file to that particular location each time. A bookmark may also be placed in this location to open a file to where the user previously left off viewing the file.
The application processing the TOC object typically determines how the Description Data Field 824 is consumed. For example an application may let a user choose to view the data in this field, or the application may simply ignore the data in this field. For example, a TOC Object for a media player may simply display a text list of available songs when it is used on a cellular telephone with limited graphics, and the same application when ran on a PC may allow full display and access to the description data 824 field's information.
The exemplary TOC Object previously described was designed with compatibility in mind and follows the ASF design guidelines. As previously described, TOC Object can be either A) a top-level object placed between the Data Object and the Index Object(s) or B) an extended header object inside the Header Extension Object. It typically works with all parsers on many devices which properly implement the ASF specification. In practice, however, there do exist parsers which do not follow the ASF specification entirely. Some of their limitations may be hardware-related, e.g., limited memory size, etc. There are some specific considerations when implementing the TOC Objects that are described in the following alternative examples.
In a first alternative example a device accepts only a fixed header object. Some devices can only handle ASF files with the Header Object of a fixed size, i.e., no header extensions. In this case, the TOC Object should be placed after the Data Object. A properly implemented parser should ignore the TOC Object if it does not know how to handle it.
In a second alternative example a streaming application may require a small header object. Streaming applications may require the TOC Object to be included in the Header Object so that the TOC information will be available at the client side before the content starts. On the other hand, the Header Object needs to be small to avoid long delay. In this case, the application may choose to include the TOC Object in the Header Extension Object. It may also choose to not include any additional description data. In other words, the TOC Object will only contain the entry lists which include the entry titles and timestamps.
Applications of the ASF TOC are provided in the following examples. Those skilled in the art will realize that other examples in addition to the ones described are possible.
Application 1: Playback a WMV file in a media player application. In this application, the player may display the EntryTitle-Time pairs obtained from the TOC Object in its playlist. The entries may be hierarchically grouped, e.g., as chapters, scenes, and/or sub-shots. When the user clicks on one of the entries, the player will directly jump to the beginning of that segment according to the timestamp (or packet offset) stored in the TOC Object. The player may also choose to display thumbnails for each entry which may be stored as the associated metadata.
Application 2: Authoring a WMV file in a video editing application program. A video editing application may offer the user the ability to create chapters, choose names for the chapters, insert personal “bookmarks”, grouping favorite scenes, etc. The chapter/bookmark/group names and their corresponding timestamps may then be stored into the TOC Object in the ASF file. The video editing application may also choose to store other additional description data, e.g., certain audiovisual DSP properties, to facilitate easy editing, fast browsing and content-based search.
Application 3: Streaming a WMV file from a video on demand (“VOD”) server. A VOD server may use the TOC Object to provide its viewers the ability to see the overview of a movie or show via chapter lists, scene lists, story boards, etc. The TOC Object may be either parsed at the server side or streamed and parsed at the client side. The viewer may click on any particular chapter or scene which will then trigger the streaming of the actual content. The TOC Object may help make the VOD contents behave very much like the viewer's local DVD contents. In fact, because the TOC Object can store any type of metadata to facilitate visualization, search and pop-up info, it could make the VOD viewing experience even richer than the current DVD viewing experience.
FIG. 9 illustrates an exemplary computing environment 900 in which the systems and methods described in this application, may be implemented. Exemplary computing environment 900 is only one example of a computing system and is not intended to limit the examples described in this application to this particular computing environment.
The computing environment 900 can be implemented with numerous other general purpose or special purpose computing system configurations. Examples of well known computing systems, may include, but are not limited to, personal computers, hand-held or laptop devices, microprocessor-based systems, multiprocessor systems, set top boxes, programmable consumer electronics, gaming consoles, Consumer electronics, cellular telephones, PDAs, and the like.
The computer 900 includes a general-purpose computing system in the form of a computing device 901 . The components of computing device 901 can include one or more processors (including CPUs, GPUs, microprocessors and the like) 907 , a system memory 909 , and a system bus 908 that couples the various system components. Processor 907 processes various computer executable instructions to control the operation of computing device 901 and to communicate with other electronic and computing devices (not shown). The system bus 908 represents any number of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.
The system memory 909 includes computer-readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). A basic input/output system (BIOS) is stored in ROM. RAM typically contains data and/or program modules that are immediately accessible to and/or presently operated on by one or more of the processors 907 .
Mass storage devices 904 may be coupled to the computing device 901 or incorporated into the computing device by coupling to the buss. Such mass storage devices 904 may include a magnetic disk drive which reads from and writes to a removable, non volatile magnetic disk (e.g., a “floppy disk”) 905 , or an optical disk drive that reads from and/or writes to a removable, non-volatile optical disk such as a CD ROM or the like 906 . Computer readable media 905 , 906 typically embody computer readable instructions, data structures, program modules and the like supplied on floppy disks, CDs, portable memory sticks and the like.
Any number of program modules can be stored on the hard disk 910 , Mass storage device 904 , ROM and/or RAM 909 , including by way of example, an operating system, one or more application programs including a media player application 103 , other program modules, and program data such as an ASF file with a TOC Object 202 . Each of such operating system, application programs, other program modules and program data (or some combination thereof) may include an embodiment of the systems and methods described herein.
A display device 902 can be connected to the system bus 908 via an interface, such as a video adapter 911 . A user can interface with computing device 902 via any number of different input devices 903 such as a keyboard, pointing device, joystick, game pad, serial port, and/or the like. These and other input devices are connected to the processors 907 via input/output interfaces 912 that are coupled to the system bus 908 , but may be connected by other interface and bus structures, such as a parallel port, game port, and/or a universal serial bus (USB).
Computing device 900 can operate in a networked environment using connections to one or more remote computers through one or more local area networks (LANs), wide area networks (WANs) and the like. The computing device 901 is connected to a network 914 via a network adapter 913 or alternatively by a modem, DSL, ISDN interface or the like.
Those skilled in the art will realize that storage devices utilized to store program instructions can be distributed across a network. For example a remote computer may store a tool such as the adaptive instrumentation runtime monitoring and analysis software. A local or terminal computer may access the remote computer and download a part or all of the software to run the program. Alternatively the local computer may download pieces of the software as needed, or distributively process by executing some software instructions at the local terminal and some at the remote computer (or computer network). Those skilled in the art will also realize that by utilizing conventional techniques known to those skilled in the art that all, or a portion of the software instructions may be carried out by a dedicated circuit, such as a DSP, programmable logic array, or the like.
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A computer memory product having stored thereon a digital media file, the memory product comprising a computer readable memory, and a data file including at least two digital data portions; a header object including a table of contents (TOC) object containing data regarding the data file; and a second data object following the first header object containing data representing digital media wherein the TOC object is disposed between the first header object and the second data object.
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This is a division, of application Ser. No. 849,620, filed Nov. 8, 1977.
BACKGROUND OF THE INVENTION
This invention relates generally to devices or apparatus for obtaining useful work from the energy of waves.
The amount of energy or power available in waves is enormous and this power is generally recognized by the damage caused. Thus, waves are usually regarded as a hindrance rather than an asset. For example, at Wick Breakwater in Scotland a block of cemented stones weighing 1,350 tons was broken loose and moved bodily by waves. Several years later, a replacement pier weighing 2,600 tons was carried away. In other instances, a concrete block weighing 20 tons was lifted vertically to a height of 12 feet and deposited on top of a pier 5 feet above the highwater mark; stones weighing up to 7,000 pounds have been thrown over a wall 20 feet high on the southern shore of the English Channel; and on the coast of Oregon, the roof of a lighthouse 91 feet above the water was damaged by a rock weighing 135 pounds.
Heretofore this enormous amount of power available in the world's oceans has been largely ignored. One reason for this lack of utilization of the available energy in the world's oceans is their very power. In other words, most devices which have been designed for capturing or converting the energy of waves to useful work have been destroyed or damaged by that very energy. This is at least partly due to the irregularity of waves which can cause jerky or irregular motion of wave energy devices. Moreover, storms frequently occur during which time wave action can become violent, thus destroying installations erected for converting the energy of the waves to useful work. Other prior art devices are not efficient in operation and convert only a very small portion of the available wave energy. For example, the actual propagation or movement of water particles in a lateral direction is only about one percent of the velocity of travel of waves. Thus, while devices floating on the surface of a body of water may be utilized to extract some of the energy of the waves themselves, these devices are not able to extract energy from the moving water itself.
Prior art devices range from elongate cylinders or like structures bobbing at the surface of the body of water for driving a propeller carried thereby, through so-called air turbines which comprise floating bodies at the surface with open bottom chambers into which waves are permitted to rise and fall for alternately compressing air in chambers to drive a turbine, up to complex bodies specifically configured to obtain rotational movement from the action of waves and moving water particles thereon to drive turbines. These last devices are commonly referred to as Salter's Duck, for example, and are more fully described on pages 21, 22, 23 and 24 of the January, 1976 issue of THE NAVAL ARCHITECT.
All such prior art devices capture or convert only a small portion of the available power in waves and in many cases are not durable enough to withstand the forces encountered in the ocean's waters or are not cost efficient.
The present invention, on the other hand, provides a unique structure which floats at the surface of a body of water and is constructed to convert the rolling or orbital motion of water particles in the waves into a linear flow of water and to then accelerate the linear flow without using any mechanical means or process. The accelerated flow is then utilized, inter alia, to drive a water wheel, turbine or the like for extracting power from the moving body of water. The linear flow of water so created may be utilized for a variety of other industrial purposes, such as extinguishing waves or collecting substances contained in the water. The densification of the energy in the waves by converting it to linear flow and then accelerating the linear flow without using any mechanical means or process results in a substantial increase in the amount of power or energy extracted from the waves, since the energy varies in proportion to the square of the velocity of the water (E=1/2 MV 2 ). Moreover, the device or apparatus according to the invention includes structure which is caused to pitch and heave with wave movement and has means for extracting power from the waves as a result of the pitching and heaving movement. Additionally, the apparatus of the present invention is normally disposed beneath the surface of the body of water and is free floating and is adapted to weather storms and the like without damage thereto, and in fact, the power extracted from the waves by the present invention remains smooth and substantially uninterrupted during varying conditions of the surface of the body of water.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an apparatus for extracting energy from waves wherein the apparatus is simple and rugged in construction and is economical to manufacture, and which includes means for densifying wave energy before converting the energy.
Another object of the invention is to provide an apparatus for extracting useful work from wave energy, wherein the apparatus is constructed to convert the rolling orbital motion of water particles in waves to linear flow and to then accelerate the linear flow and direct the accelerated linear flow through a turbine or the like to produce useful work.
Yet another object of the invention is to provide an apparatus for converting wave energy to useful work, wherein the apparatus is constructed to pitch and heave with wave motion and wherein means is connected with the apparatus for extracting energy upon pitching motion in both directions, as well as upon heaving motion of the apparatus.
A still further object of the invention is to provide an apparatus which is constructed to extract useful energy from wave power and wherein the apparatus is free floating and is normally disposed just beneath the surface of the body of water and has an upper surface thereof normally disposed substantially parallel to the surface of the body of water and configured to convert the rolling, orbital motion of water particles in the waves to linear flow and to accelerate the linear flow without using any mechanical means or process to obtain work therefrom, the upper surface having means to prevent backwash of waves thereon.
Yet another object of the invention is to provide an apparatus for extracting useful energy from waves wherein the apparatus is buoyant and is configured and constructed to pitch and heave with wave motion and has weight means associated therewith to enhance the inertia effect to offset the reverse torque produced by the turbine or other power takeoff means.
An even further object of the invention is to provide an apparatus for converting wave energy to useful work wherein the apparatus includes means for changing the rolling, orbiting motion of water particles in the waves to linear flow and for accelerating the linear flow and including means for utilizing the accelerated linear flow to produce work, and also having means for driving a power output device upon pitching motion of the apparatus in both directions as well as upon heaving motion of the apparatus.
It is a further object of this invention to provide a method of extracting energy from waves, wherein the wave energy is densified before it is converted to useful work.
Still another object of this invention is to provide a method of extracting energy from waves, wherein the rolling, orbital movement of water particles in the waves is converted to linear flow, and the linear flow is then accelerated and directed through a turbine or water wheel and the like.
Another object of the invention is to obtain useful work from the energy of waves by extracting the energy in both directions of pitching motion of an apparatus floating on the waves, as well as from the heaving motion of the apparatus.
Yet another object of the invention is to provide a method of extracting energy from waves, wherein weights are caused to shift with movement of an apparatus provided to extract the energy, whereby the pitching movement or inertia is enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat diagrammatic view illustrating the manner in which water particles travel during wave propagation.
FIG. 2 is a diagrammatic view illustrating the manner in which the apparatus of the present invention operates to convert the rolling or orbital motion of the water particles in the waves to linear flow.
FIG. 3 is a further view similar to FIG. 2 illustrating the manner in which the apparatus of the invention operates to convert the rolling motion of water particles to linear flow and also operates to prevent backwash of waves onto the apparatus.
FIG. 4 is a diagrammatic view illustrating the manner in which the force vector of the movement of water particles in the waves operates upon the apparatus of the invention to cause it to pitch in opposite directions.
FIG. 5 is a diagrammatic view illustrating the manner in which the apparatus of the present invention pitches and heaves as waves travel therepast.
FIG. 6 is a perspective view of an apparatus according to the invention illustrating the manner in which power takeoff turbines or like water driven devices may be disposed within the flow channels defined on the upper surface of the apparatus to extract energy from the accelerated linear flow of water.
FIG. 7 is a fragmentary plan view of the apparatus of FIG. 6 showing a plurality of devices connected together through a universal coupling.
FIG. 8 is a view similar to FIG. 7 of a modified form of the invention.
FIG. 9 is a view similar to FIG. 7 of a further modification of the invention.
FIG. 10 is a view in cross section of the apparatus of the invention showing the construction thereof from concrete.
FIG. 11 is a view in cross section of the apparatus of the invention showing a first form of weight means or inertia device therewithin.
FIG. 12 is a view similar to FIG. 11 showing a different type of weight means or pendulum in the device for imparting inertia to the pitching movement thereof.
FIG. 13 is a view in section showing a preferred form of the apparatus according to the invention with the apparatus in a neutral position.
FIG. 14 is a view in section of the apparatus of FIG. 13, showing the apparatus pitched in one direction.
FIG. 15 is a view similar to FIG. 14, with the apparatus pitched in the opposite direction.
FIG. 16 is a view with portions in section of a modified form of apparatus according to the invention wherein internal and external weights are used to impart inertia movement to the apparatus and wherein an outrigger float or vane device is used for enhancing pitching movement of the apparatus.
FIG. 17 is a view similar to FIG. 13 of a modification of the invention in FIG. 13, wherein four chambers are used inside the device rather than two as in FIG. 13.
FIG. 18 is a view similar to FIG. 15 of the apparatus of FIG. 17.
FIG. 19 is a view similar to FIG. 17 of a still further form of the invention wherein four chambers are used.
FIG. 20 is a view similar to FIG. 18 of the apparatus of FIG. 19.
FIG. 21 is a view similar to FIG. 16 of a modification of the invention shown in FIG. 16, wherein four chambers are used instead of two chambers as in FIG. 16.
FIG. 22 is a view with portions shown in section of a still further form of the invention, wherein external power takeoff means is connected with the apparatus to obtain useful work from the pitching motion of the apparatus.
FIG. 23 is a view similar to FIG. 22 of a modification of the invention of FIG. 22 wherein external power takeoff means is used and includes means for extracting energy from both the pitching motion of the apparatus in both directions and from the heaving motion of the apparatus.
FIG. 24 is a view of a still further modification of the invention, wherein a double acting piston means is connected with the apparatus to obtain useful energy from the pitching motion of the apparatus.
FIG. 25 is a view similar to FIG. 24 showing a double acting piston means for extracting useful energy from the heaving motion of the apparatus.
FIGS. 26 and 27 are elevation and plan views, respectively, of yet another modification of the invention wherein a butterfly-like construction is used with floats at opposite sides of a central body.
FIG. 28 is a view in elevation of a modification of the invention shown in FIG. 26 wherein only one movable float member extends from one side of the apparatus.
FIGS. 29-35 are somewhat diagrammatic views in elevation with portions shown in section of further forms or modifications or variations of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, wherein like reference numerals indicate like parts throughout the several views, the movement of water particles in waves is indicated somewhat diagrammatically in FIG. 1 and, as illustrated, water particles in the waves move or propagate in a generally horizontal direction with an orbital or circular motion, the diameter of the orbital or circular motion being approximately equal to the height of the waves (the distance D from the crest to the trough). The water drift on the surface is only about one percent of the speed of travel of the waves in deep water. Thus, although the wave velocity may typically be about 4 meters per second, the actual water drift or lateral movement of water is much less. However, the circular movement of the water particles is about 1.56 times the wave velocity. Accordingly, conversion of the circular or orbital movement of the water particles to linear flow and acceleration thereof can result in water velocity of 50 meters per second or more. Therefore, since the energy equals the mass times the square of the speed of the moving water, the density of the energy or energy available is increased substantially by merely increasing the velocity of the water.
The manner in which the apparatus of the invention acts to convert the rolling or orbital motion of water particles to linear flow is somewhat diagrammatically illustrated in FIGS. 2 and 3. As can be seen, the apparatus includes a buoyant body 10 having a leading edge 11, a trailing edge 12, and a convex curved upper surface 13 extending between the leading and trailing edges 11 and 12. The upper surface 13 defines an upwardly sloping ramp from the leading edge toward the trailing edge and the ramp curves sharply downwardly at the trailing edge thereof to eliminate or substantially prevent backwash of waves onto the upper surface (see FIG. 3). Thus, as noted above, with this arrangement the flow of water may be converted to a linear stream and accelerated to 50 meters per second or more. Moreover, the rolling or orbital motion of the water particles has both horizontal and vertical force components and the buoyant body 10 of the present invention is configured to take advantage of the vector addition of these horizontal and vertical force components, as illustrated in FIG. 4, to obtain maximum force on the body to impart pitching motion thereto. As seen in FIG. 5, the propagation of waves past the body 10 results in the body pitching about an angle α and heaving a distance H. In order to obtain maximum force and movement of the body 10, the width of the body is preferably equal to or less than one-half the wave length and the length of the body is preferably equal to or less than the wave length. Additionally, the center of flotation of the apparatus preferably equals the center of gravity of the apparatus. With these parameters, the upper surface 13 of the apparatus is substantially nearly always parallel with the surface of the body of water and is beneath the surface. Accordingly, very smooth action is obtained with none of the jerkiness and erratic motion found in prior art devices.
In FIG. 6 a first form of the apparatus A includes the buoyant body 10 with a plurality of substantially tear drop-shaped, parallel, spaced apart superstructures 14 on the upper surface thereof defining water flow channels 15 therebetween which grow smaller in cross section toward the apex of the upper surface 13. Disposed and supported within the water flow channels 15 are power takeoff devices such as water wheels, turbines or the like 16 supported in any suitable manner and connected with a shaft S to drive a generator G. A water wheel 16' is indicated in dot and dash lines in this figure. The water wheels or turbines may, of course, drive other devices rather than the generator G if desired. Thus, in view of the previous discussion, it will be apparent that the water wheels 16' or turbines 16 are substantially always disposed in a high velocity stream or jet of water to which fly wheels may be attached with the common axis, and accordingly, a substantial amount of power is smoothly and continuously extracted from the water movement in the waves. This arrangement differs considerably from prior art arrangements, as exemplified, for example, in U.S. Pat. No. 3,965,679, wherein a ramp 18 is supported in a fixed position relative to the bottom of a body of water and water deflectors 34 and 36 are arranged to throw or direct waves upwardly against paddle wheels 30.
In FIG. 7 a plurality of buoyant bodies 10a and 10b are coupled together by means of a universal joint or other suitable structure 17, whereby a bank of the devices may be joined together and extended over a considerable area for extracting energy from waves.
In FIGS. 8 and 9 further buoyant bodies 10' and 10" are illustrated wherein differently configured superstructures 14' and 14" are provided for accelerating the flow of water through the water flow channels 15.
In FIG. 10 a preferred construction of the buoyant body 10 and superstructure 14 is illustrated, and as can be seen, a steel or wire mesh screen 18 is formed into the general shape of the buoyant body and concrete 19 is then applied to the screen 18 to form the buoyant body and superstructure. This construction is both economical and exceptionally strong and is less subject to damage from wave action during storms and the like than are prior art devices. Of course, other materials could be used in the construction of the apparatus, but it has been found that reinforced concrete applied over the screen 18, as described, provides a superior structure.
In order to increase the inertia of the pitching movement of the body 10, it has been found that the mass or weight may be readily increased at the leading edge 11' and the trailing edge 12' to form a buoyant body 10a which has a larger inertia than a similar, unweighted body. Moreover, it has been found that a moving mass works to cancel the counterforce of the water wheel, turbine or the like during use and a very high torque efficiency can be obtained by placing a track 20 within the body 10a and placing a weight 21 thereon. Accordingly, as the body 10a pitches during use, the weight 21 shifts fore and aft enhancing the inertia of the pitching movement and cancelling the counterforce imparted by the turbine or other power takeoff device, particularly in extracting energy out of the pitching movmeent as described below.
In FIG. 12 a similar approach is illustrated wherein a pendulum weight 22 is supported inside the body 10b rather than the rolling weight as in FIG. 11.
A first, preferred form of the invention is illustrated in FIGS. 13, 14 and 15 and in this form of the invention, the body 10c has weighted leading and trailing edges 11' and 12', respectively, between which the convex curved upper surface 13 extends and on which the superstructure 14 is formed. The interior of the body 10c is divided into two chambers 23 and 24 interconnected at their top by a passageway 25 for flow of air between the chambers. A volume or body of water 26a and 26b is contained in the chambers 23 and 24, respectively, for flow therebetween to drive a turbine or other suitable water wheel or like device 27 supported in any suitable manner between the chambers 23 and 24. In order that the bodies of water 26a and 26b may be used to drive the turbine 27, first and second inlet conduits 28 and 29 extend from the chambers 23 and 24, respectively, to adjacent the upper portion of the turbine 27 and one-way valves 30 and 31 are associated with the lower ends of the conduits 28 and 29 which extend into the bodies of water 26a and 26b for flow of water from the respective chambers upwardly through the respective conduits to the upper portion of the turbine. First and second outlet conduits 32 and 33 extend from adjacent the bottom portion of the turbine 27 into the respective chambers 23 and 24 and one-way vlaves 34 and 35 control flow through the outlet conduits 32 and 33 such that when the body 10c pitches in a first direction, as illustrated in FIG. 14, the body of water 26b flows upwardly through valve 31 and conduit 29 over the turbine 27, driving the turbine and thence exiting from conduit 32 and valve 34 into chamber 23. Similarly, when the body 10c pitches in the opposite direction, as seen in FIG. 15, the body of water 26a flows from chamber 23 through valve 30 upwardly through conduit 28 onto the turbine 27, driving the turbine in a counterclockwise direction and exiting through conduit 33 and valve 35 into the chamber 24 to replenish the body of water 26b. Thus, by this structure the turbine is substantially continuously driven in the same direction upon pitching motion of the body in both directions. Neither water wheels 16' or turbines 16 in the water flow channels 15 on the upper surface of the body 10c are shown in these figures. However, the water wheels 16' or turbines 16 are preferably provided in the water flow channels for extraction of the energy in the moving surface water.
In FIG. 16 a modified two chamber version of the apparatus is indicated at A' and includes a buoyant body 36 generally cylindrical in cross sectional configuration and having a first interior wall 37 extending along a chord thereof subdividing the interior of the body into a bottom chamber 38 and an upper chamber which is in turn divided by a second interior wall 39 into a pair of chambers 40 and 41. An air passage 42 extends through the wall 39 establishing communication between the chambers 40 and 41 and volumes or bodies of water 43 and 44 are in the chambers 40 and 41 for flow therebetween. In this connection, a turbine 45 is supported in the wall 39 and first and second inlet conduits 46 and 47 extend from the respective bodies of water 43 and 44 to the upper portion of the turbine 45 for discharge of water onto the turbine to cause it to rotate. One-way valves 48 and 49 are in the conduits 46 and 47 for controlling flow therethrough. Additionally, one-way outlet valves 50 and 51 are provided at the bottom of the turbine opening into the respective chambers 40 and 41, whereby when the apparatus A' pitches in a first direction, water flows upwardly through the valve 49 and conduit 47 and discharges onto the turbine 45 and exits from the turbine through valve 50. Similarly, when the body or apparatus pitches in a second direction, water flows upwardly through valve 48 and conduit 46 and discharges onto the turbine 45 to cause the turbine to continue to rotate in the same direction and the water then discharges from valve 51. A moving weight 52 is disposed in the bottom chamber 38 for rolling movement along the inner surface of the bottom portion of the body 36 to enhance the inertia of movement of the body in its pitching motion. Further, an arm 53 extends from the leading side of body 36 and has a weight 54 supported thereon to further increase the inertia of movement of the body in its pitching movement. A further arm or projecting surface or body 55 extends from the trailing edge of the body 36 and carries a float 56 on the outer edge thereof. Vanes 57 and 58 are supported from the float 56 for cooperation with waves or flowing water and the vanes 57 and 58 are constructed and oriented such that they take maximum advantage of the force vectors of the moving water particles in the body of water. A superstructure 14' extends between the body 36 and vane 57 for channeling the linear flow of water over the apparatus to increase the velocity thereof, as in the previous forms of the invention.
A further form of the invention is illustrated in FIGS. 17 and 18, and in this form of the invention four different chambers 59, 60, 61 and 62 are provided with volumes or bodies of water 63, 64, 65 and 66 therein. Chambers 59 and 61 are in communication at their upper portions by means of a conduit 67 which enables air to flow from chamber 59 to 61 and vice versa, and chambers 60 and 62 are in communication at their upper end by means of a conduit 68 which enables air to flow between chambers 60 and 62. Further, an opening 69 is formed through wall 70 separating chambers 60 and 61, whereby the bodies of water 64 and 65 are permitted to flow back and forth between the chambers 60 and 61. A turbine 71, or other suitable water driven device, is supported in the body 10d between chambers 60 and 61 and a pair of inlet conduits 72 and 73 extend from the chambers 59 and 62 to adjacent the top portion of the turbine 71 for alternately conducting water from the respective chambers to the turbine to cause it to rotate. One-way valves 74 and 75 are associated with the inlet conduits 72 and 73 for controlling flow therethrough in one direction. Outlet conduits 76 and 77 extend from lower portions of the turbine 71 back to the chambers 59 and 62 for conveying the water thereto from the turbine 71. Thus, as seen in FIG. 18, when the apparatus pitches to the right, the body of water 63 in chamber 59 flows through valve 74 and conduit 72 and impinges upon the turbine 71 to cause the turbine to turn. The water exits the turbine through conduit 77 and valve 78 into the chamber 62. At the same time, water 64 in chamber 60 flows through opening 69 into chamber 61, compressing the air in chamber 61 and forcing it through conduit 67 into chamber 59 to pressurize the water in chamber 59 and enhance or increase its flow through the turbine 71. Similarly, the inflowing water from conduit 77 to chamber 62 pressurizes the air in chamber 62 which is communicated through conduit 68 with chamber 60 pressurizing the water in chamber 60 and enhancing its flow into chamber 61 to in turn enhance or increase pressurization of the air. Thus, a multiplication of pressures is obtained by the interconnection of the various chambers with the result that a pressurized flow of water through the turbine is caused. A similar effect is obtained when the apparatus pitches to the left.
A still further form of the invention is illustrated in FIGS. 19 and 20 and the operation of this form of the invention is substantially the same as that in FIGS. 17 and 18, in that four separate chambers 80, 81, 82 and 83 are interconnected for flow of air and water in a manner to increase the pressure flow of water, as described above. The various components of this form of the invention which correspond to the components of the form of the invention in FIGS. 17 and 18 are indicated by reference numerals primed. Thus, in this form of the invention, when the buoyant body 10d' is pitched to the right, as in FIG. 20, the body of water 64' in chamber 82 flows through opening 69' into chamber 83, compressing the air therein and forcing it through conduit 68' into chamber 80, pressurizing the body of water 63' in that chamber and enhancing its flow through valve 74', conduit 72' and thence through the turbine or the like 71' and through valve 79' into chamber 81.
In FIG. 21 a modification of the four chamber apparatus is indicated generally at A" and comprises a body 84 which is substantially cylindrical in shape as in the FIG. 16 embodiment and instead of having a lower chamber 38 with a weight 52 therein, the interior of the body 84 is subdivided into four chambers 80', 81', 82' and 83'. A turbine 45' is supported in the body and has a pair of inlet conduits 85 and 86 extending from the bodies of water in the respective chamber 80' and 81' to adjacent the upper portion of the turbine for discharging water onto the turbine. Outlet valves 87 and 88 extend from a lower portion of the turbine into the respective chambers 80' and 81' for through flow of water from the inlet conduits through the turbine and to the opposite chamber. The operation of water flowing between the chambers to pressurize air and thus pressurize and enhance flow of water between the chambers is the same as described in connection with FIGS. 17-20. Additionally, this form of the invention has members 53' and 55' projecting from the leading and trailing sides thereof, respectively, and a weight 54' is carried by the outer end of member 53', whereas pairs of vanes 57a and 57b and 58a and 58b are carried by the member 55' similarly to the corresponding members in FIG. 16. While a superstructure 14' is now shown in this figure, it should be understood that such could be provided along with its function, if desired.
In FIG. 22 a further modification of the invention is indicated generally at 89, and in this form of the invention the turbine or power takeoff structure 90 is external of the buoyant body 91. The buoyant body 91 is connected to the power takeoff structure 90 by an elongate connecting rod 92 secured at one end 93 on the axis of the center of buoyancy of the body 91 and secured at its other end 94 to the power takeoff structure 90. Suitable slotted brackets 95 and 96 are provided on the buoyant body 91 on opposite sides of the pivot axis or center of buoyancy of the body 91 and piston rods 97 and 98 are connected therewith and extend into the power takeoff structure 90 and are connected to pistons 99 and 100 reciprocable in cylinders 101, 102, respectively. The power takeoff structure 90 is supported in a relatively stable position in the body of water by means of vanes 103, 104 carried at the bottoms of suitable supports 105 and 106, respectively.
A turbine or water wheel or the like 107 is mounted within a housing 108 inside the power takeoff structure 90 and a pair of inlet passages 109 and 110 extend to the turbine or the like from opposite ends of cylinder 102 through valves 111 and 112, whereby as the piston 100 reciprocates in respective opposite directions, a liquid, such as water or the like, contained within cylinder 102 is forced through the respective inlet passage depending upon the direction of movement of piston 100 and past the turbine or other suitable water driven device to produce useful work. The water or other suitable liquid or fluid supplied to the turbine or the like via inlet passages 109 and 110 is exhausted from the turbine or the like via outlet passages 113 and 114 through one-way valves 115 and 116, respectively. Similarly, a pair of inlet passages 109a and 110a are provided in communication with opposite ends of the other piston cylinder 101 and corresponding outlet passages 113a and 114a are also provided, with the passages being controlled by suitable one-way valve means. Thus, pitching movement of the buoyant body 91 in both directions causes reciprocation of the pistons 99 and 100 to substantially continuously force fluid through the turbine or other water driven means 107 to produce useful work.
In FIG. 23 a further modification of the invention is indicated generally at 117 and is similar to the invention shown in FIG. 22, except that the superstructure 14 is provided on top of the buoyant body 91' and the connecting rod 92' extends from the axis of rotation or center of buoyancy of the body 91' to a piston 118 reciprocable in a cylinder 119 rather than being rigidly secured to the structure 90', as in FIG. 22. Suitable inlet and outlet passages extend from the respective cylinders 101', 119 and 102' to the turbine or other suitable water driven means 107' to drive the turbine or the like upon pitching movement of the body 91' in both directions, as well as upon heaving movement thereof due to the connection with rod 92' and piston 118. A water vane or the like 120 is connected with the structure 90' by means of a connecting member 121 to tend to immobilize the structure 90' in the body of water while the buoyant body 91' is moving, whereby the movement of the body 91' can be converted into movement of the pistons 99', 118 and 100' to produce useful work.
In FIG. 24 a still further form of the invention is indicated generally at 122 and comprises a buoyant body 123 with a superstructure 14 thereon as previously described. A suitable slotted bracket 124 is carried by the body 123 at the leading edge thereof and suitable weight means or the like 125 is also carried by the body at the leading edge for enhancing the pitching movement thereof, as described in connection with previous forms of the invention. A connecting rod 126 extends from the slotted bracket 124 to a piston 127 reciprocable in a cylinder 128 formed in a power takeoff structure 129 which has suitable water vanes 130 and 131 carried thereby to tend to immobilize the structure 129 in the body of water. Resilient bumpers 132 and 133 are disposed in the cylinder 128 at opposite ends thereof for cushioning travel of the piston 127 at its opposite limits of travel. A turbine or other suitable water drive device 134 is supported adjacent the cylinder 128 and a pair of inlet conduits 135 extend from opposite ends of the cylinder 128 to the turbine or the like 134 for conveying pressure fluid thereto to drive the turbine or the like in both the up and down pitching movement of the body 123. Suitable valves 136 and 137 control flow through the inlet conduits 135 for appropriate movement of water through the conduits upon movement of the piston in its respective opposite directions. Similarly, a pair of outlet conduits 138 and 139 extend from the turbine or the like 134 back to the opposite ends of the cylinder 128 and flow therethrough is controlled by a pair of valves 140 and 141, respectively.
In FIG. 25 yet another form of the invention is indicated at 142, and in this form of the invention the buoyant body 123' has a superstructure 14 thereon as in FIG. 24, but rather than the piston rod 126 connected for movement upon pitching motion of the body, a rod 143 is secured to the center of buoyancy or axis of the center of buoyancy of the body 123' and extends downwardly and is rigidly connected with the structure 129' which defines a cylinder 128' therewithin having a piston 144 reciprocable in the cylinder 128', the piston being carried by a rod 145 extending downwardly from the cylinder 128' and connected to a water vane 146, whereby up and down heaving motion of the body 123' causes the cylinder 128' to move up and down therewith relative to the piston 144 which is maintained in a relatively immobile position by the vane 146. A turbine or other suitable water driven means 134' is connected to be operated just as in the FIG. 24 embodiment.
Yet another form of the invention is indicated generally at 147 in FIGS. 26 and 27 and comprises a central buoyant body 148 of substantially cylindrical configuration and a pair of substantially identically constructed buoyant body members or wings 149 and 150 pivotally joined to the axis of central member 148 by connecting rods or bars 151 and 152, respectively. The outer ends or edges of the members 149 and 150 have weights 153 and 154 thereon for enhancing the pitching movement thereof and water vanes 155 and 156 are also connected to the wings at their outer ends or edges to take maximum advantage of the motion or movement of the water particles in the waves. The apparatus shown in FIG. 26 may be used to operate an internal turbine or other water driven device, as in FIGS. 13-21, for example, or it may be used to operate external turbines or water driven devices, such as in FIGS. 22-25. Moreover, the apparatus may be used to operate a combination of elements as previously described.
Yet another form of the invention is indicated generally at 157 in FIG. 28 and this form of the invention is similar to that shown in FIGS. 26 and 27, except that only one wing body member 149' is provided and the cylindrical central body portion 148' is integral with the tapered body portion 158 extending to the right as viewed in FIG. 28 and forming the second wing-like body member. Weights 153' and 154' are provided at the outer ends of the tapered body members and water vanes 155' and 156' are also carried thereby, as in the form of the invention in FIGS. 26 and 27. This form of the invention may also be used to drive either internal or external turbine means or the like or a combination thereof as in the previously described forms of the invention.
In FIGS. 29-35 several different variations of buoyant body members are illustrated at 159-165, respectively, and each of the buoyant body members has weight means associated therewith and/or water vanes as in the previously described forms of the invention. Details of construction of these forms of the invention have been omitted, since it is believed that in view of the foregoing disclosure the specific construction and arrangement of parts in these forms of the invention will be readily apparent to those skilled in the art.
Thus, while specific forms and constructions of the invention have been illustrated and described, it should be noted that various other configurations of the buoyant body member may be provided and various materials may be used in its construction.
Essentially, the present invention provides a unique means for extracting energy from the ocean's waves, wherein the apparatus according to the invention has means for extracting energy from the pitching motion of the apparatus caused by the waves in both directions of pitching thereof, and in addition, means is provided for extracting energy due to the heaving motion of the apparatus. Further, the apparatus is uniquely configured to densify the energy in the waves by converting the rolling or orbital motion of water particles in the waves to linear motion and then accelerating the linear motion of water particles and utilizing the accelerated linear flow to drive a turbine or like water driven means.
Moreover, the present invention is uniquely suitable for extracting or collecting uranium from sea water merely by placing a known material on the upper surface of the buoyant body which, through ionic exchange removes uranium from the sea water as it flows over the surface.
Still further, the apparatus of the present invention is useful not only to extract power from the waves in the Earth's oceans, but is also effective to create still water areas for use as harbors or protected areas and the like, since the effect of the apparatus according to the invention is to dampen or extinguish waves. The same principle may be used to contain oil spills and the like, since the high velocity flow of water created over the surface of the apparatus forms a unidirectional flow of water which by strategically placing a plurality of apparatus according to the invention can be used to direct an oil spill or the like toward a central gathering area or the like. Similarly, the apparatus according to the invention can be used to stir and dissipate pollutants in heavily polluted areas of water adjacent coast lines and the like where the water movement is not adequate to dissipate pollutants spilled thereinto.
Additionally, the apparatus of the present invention may be utilized with existing technology to produce hydrogen from the energy of the waves when the energy is not directly converted to electrical energy and used immediately, or transferred to shore for later recovery of the hydrogen and use as desired.
As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is, therefore, illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperative equivalents are, therefore, intended to be embraced by those claims.
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An apparatus and method for obtaining useful work from or with waves includes a buoyant body having a leading edge and a trailing edge, and a convex upper surface extending between the leading and trailing edges. The upper surface is configured with a gradually sloping shape from the leading edge toward the trailing edge and terminates at the trailing edge in a sharply oppositely sloping surface, whereby the circular or orbital motion of water particles in waves is converted by the upper surface to linear flow of the water particles, and waves traveling across the surface from the leading to the trailing edge are not damped or extinguished by backwash of waves from the trailing edge toward the leading edge. Upstanding structures on the upper surface define open-ended venturi-shaped water flow channels across the upper surface which increase the velocity of the linear flow of water across the upper surface, and water-driven devices are disposed in the water flow channels to obtain work from the accelerated linear flow of water. The buoyant body floats at the surface of the body of water, with the upper surface of the buoyant body disposed beneath and substantially parallel to the surface of the water, and the configuration of the buoyant body is such that it undergoes both pitching and heaving motion as waves move therepast. Devices may be attached to the buoyant body and/or positioned therewithin to obtain work from the pitching and heaving motion of the buoyant body.
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RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 10/725,850, filed Dec. 2, 2003.
FIELD OF THE INVENTION
The present invention relates to high-performance complementary metal oxide semiconductor (CMOS) circuits in which carrier mobility is enhanced by utilizing different semiconductor surface orientations for p-type field effect transistors (FETs) and n-type FETs. More particularly, the present invention relates to methods for fabricating planar substrate structures with different surface crystal orientations, and to the hybrid-orientation substrate structures produced by such methods.
BACKGROUND OF THE INVENTION
The CMOS circuits of current semiconductor technology comprise n-type FETs (nFETs), which utilize electron carriers for their operation, and p-type FETs (pFETs), which utilize hole carriers for their operation. CMOS circuits are typically fabricated on semiconductor wafers having a single crystal orientation. In particular, most of today's semiconductor devices are built on Si having a (100) surface orientation.
It is known that electrons have a high mobility in Si with a (100) surface orientation and that holes have high mobility in Si with a (110) surface orientation. In fact, hole mobility can be about 2 to 4 times higher on a 110-oriented Si wafer than on a standard 100-oriented Si wafer. It would therefore be desirable to create a hybrid-orientation substrate comprising 100-oriented Si (where nFETs would be formed) and 110-oriented Si (where pFETs would be formed).
Planar hybrid substrate structures with different surface orientations have been described previously (see, for example, co-assigned U.S. application Ser. No. 10/696,634, filed Oct. 29, 2003, and co-assigned U.S. application Ser. No. 10/250,241, filed Jun. 17, 2003).
FIGS. 1A-1E show, in cross section view, some prior art examples of planar hybrid-orientation semiconductor substrate structures comprising bulk semiconductor substrate 10 , dielectric trench isolation regions 20 , semiconductor regions 30 with a first surface orientation (e.g., j′k′l′), and semiconductor region 40 with a second surface orientation (e.g., jkl). In the structure of FIG. 1A , semiconductor regions 30 and 40 are both directly on bulk substrate 10 , with semiconductor region 40 and bulk substrate 10 having the same orientation. The structure of FIG. 1B differs from that of FIG. 1A only in that semiconductor regions 30 are on buried oxide (BOX) layer 50 instead of directly on bulk substrate 10 . The structures of FIGS. 1C-1E differ from those of FIGS. 1A-1B by the thickness of BOX layers 50 and 50 ′ and by the depth of trench isolation structures 20 and 20 ′.
FIGS. 2A-2B show, in cross section view, previous examples of how integrated CMOS circuits comprising at least one pFET on a (110) crystallographic plane of Si and at least one NFET on a (100) crystallographic plane of Si may be advantageously disposed on the hybrid-orientation substrate structure of FIG. 1B . In FIG. 2A , a bulk Si substrate 120 with 100 orientation has regions 130 of 110-oriented Si on BOX layer 140 , and regions 150 of regrown 100-oriented Si on bulk substrate 120 . pFET devices 170 are disposed on 110-oriented regions 130 and nFET devices 180 are disposed on 100-oriented regions 150 . In FIG. 2B , a bulk Si substrate 180 with 110 orientation has regions 190 of 100-oriented Si on a BOX layer 140 and regions 200 of regrown 110-oriented Si on bulk substrate 180 . pFET devices 210 are disposed on 110-oriented regions 180 and nFEET devices 220 are disposed on 100-oriented regions 190 .
FIGS. 3A-3I show, in cross section view, the steps of a prior art method used to form the structure of FIG. 1B . Specifically, FIG. 3A shows the starting Si substrate 250 , and FIG. 3B shows substrate 250 after formation of BOX layer 260 and silicon-on-insulator (SiOI) device layer 270 . Si substrate 250 may be 110- (or 100-) oriented, and SiOI device layer 270 would be 100- (or 110-) oriented. SiOI layer 270 may be formed by bonding or other methods. After depositing protective dielectric (preferably SiN x ) layer 280 to form the structure of FIG. 3C , SiOI device layer 270 and BOX layer 260 are removed in selected areas to form openings 290 extending to Si substrate 250 , as shown in FIG. 3D . Openings 290 are lined with a dielectric (preferably SiN x ) which is then etched to form sidewall spacers 300 , as shown in FIG. 3E . Next, epitaxial Si 310 is selectively grown in openings 290 to produce the structure of FIG. 3F , which is planarized back to form the structure of FIG. 3G . Protective dielectric 280 is then removed by a process such as polishing to form the structure of FIG. 3H with coplanar, differently oriented Si device layers 310 (on bulk Si substrate 250 ) and 320 (on BOX layer 260 ). FIG. 3I shows the completed substrate structure after shallow trench isolation areas 330 have been formed in the structure of FIG. 3H .
However, for many applications, it would be desirable to have both of the differently oriented Si regions on a BOX. Such structures are possible, but not easy, to produce by variations of the method of FIGS. 3A-3I . For example, the structure of FIG. 4 may be produced by replacing Si substrate 250 in FIG. 3A with a SiOI substrate 400 comprising substrate 410 , BOX layer 420 , and Si layer 430 to produce differently oriented single crystal regions 320 with a first orientation and 440 with a second orientation matching that of semiconductor layer 430 . However, the use of two BOX layers adds extra complexity to the process and produces structures where one of the hybrid orientations is significantly thicker than the other (a disadvantage when both layers need to be thin). In addition, selective epitaxial Si growth can be tricky; defects are likely to nucleate on the sides of sidewall spacers 300 (shown in FIGS. 3E-3F ), especially when openings 290 are small (e.g., less than 500 nm in diameter).
In view of the above, it would be desirable to have simpler and better methods (i.e., those that do not require epitaxial regrowth) to form planar hybrid-orientation semiconductor substrate structures, especially planar hybrid-orientation semiconductor-on-insulator (SOI) substrate structures wherein the differently oriented semiconductors are disposed on a common BOX layer.
In addition, it would be desirable to have integrated electrical circuits on such planar hybrid-orientation SOI substrates wherein the electrical circuits comprise pFETs on a (110) crystallographic plane and nFETs on a (100) crystallographic plane.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a planar hybrid-orientation SOI substrate structure with a surface comprising at least two clearly defined single-crystal semiconductor regions with different surface orientations, wherein the differently oriented semiconductor regions are disposed on a common BOX layer. The term “clearly defined” is used herein to denote that the surface regions of a given surface orientation are macroscopic and not merely single grains of polycrystalline Si.
It is a related object of the present invention to provide methods for fabricating such a planar hybrid-orientation semiconductor substrate structure.
It is a further object of the present invention to provide methods for fabricating similar hybrid-orientation semiconductor substrate structures on a variety of support layers.
It is yet another object of the present invention to provide integrated circuits (ICs) on the hybrid-orientation substrates of the present invention, wherein the ICs comprise pFETs on a (110) crystallographic plane and nFETs on a (100) crystallographic plane.
In accordance with the above listed and other objects, new methods are provided for forming a variety of planar hybrid-orientation semiconductor substrate structures. Common to all methods are three basic steps, by which the orientation of selected semiconductor regions may be changed from an original orientation to a desired orientation:
forming a bilayer template layer stack comprising a first, lower single crystal semiconductor layer (or substrate) having a first orientation and a second, upper (typically bonded) single crystal semiconductor layer having a second orientation different from the first;
amorphizing one of the layers of the bilayer template stack in selected areas (by ion implantation through a mask, for example) to form localized amorphized regions; and
recrystallizing the localized amorphized regions using the non-amorphized layer of the stack as a template, thereby changing the orientation in the localized amorphized regions from an original orientation to a desired orientation.
To minimize the possibility of lateral templating, the sides of the regions selected for amorphization and templated recrystallization would typically be isolated from adjacent crystalline regions, for example, by trenches. The trenches may be formed and filled before amorphization, formed and filled between amorphization and recrystallization, or formed after amorphization and filled after recrystallization.
In one embodiment of the present invention, the basic steps above are incorporated into a method for forming a planar hybrid-orientation SiOI substrate structure. A 100-oriented Si substrate is used for the first, lower layer of the bilayer template stack and a 110-oriented Si layer for the second, upper layer of the bilayer template stack. The uppermost portion of the template stack is amorphized in selected areas to a depth that ends in the underlying 100-oriented Si substrate. The amorphized Si regions are then recrystallized into 100-oriented Si, using the underlying 100-oriented Si as a template. Following these steps of patterned amorphization and recrystallization, which leave surface regions of 100-oriented Si in the treated areas and surface regions of 110-oriented Si in the untreated areas, a buried oxide (BOX) layer is formed by oxygen implantation and annealing (e.g., a “Separation by Implantation of Oxygen” or SIMOX process).
In another embodiment of the present invention, the basic steps above are incorporated into a another method to form a planar hybrid-orientation SiOI substrate structure. In this method, a 110-oriented SiOI layer on a BOX layer is used for the first, lower layer of a bilayer template stack, and a 100-oriented Si layer is used for the second, upper layer of a bilayer template stack. The lowermost portion of the bilayer template stack is then amorphized in selected areas from the BOX layer up to a depth ending in the upper template layer. The amorphized Si regions are then recrystallized into 100-orientated Si, using the upper 100-oriented Si layer as a template. The uppermost portion of the bilayer template is then removed by a process such as polishing to leave coplanar surface regions of 110-oriented Si (in the untreated areas) and 100-oriented Si (in the treated areas).
The basic steps of the present invention can be easily adapted in whole or in part to form planar hybrid-orientation semiconductor structures on different substrates (e.g., bulk, thin or thick BOX, insulating or high resistivity substrates), or to form planar hybrid-orientation semiconductor substrate structures having three or more surface orientations.
Yet another aspect of the present invention provides integrated circuits on the planar hybrid-orientation semiconductor substrates of this invention, wherein the integrated circuits comprise pFETs on a (110) crystallographic plane and nFETs on a (100) crystallographic plane.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages will be more readily apparent and better understood from the following detailed description of the invention, in which:
FIGS. 1A-1E show, in cross section view, some examples of prior art planar hybrid-orientation semiconductor substrate structures, wherein the first of two semiconductor orientations is disposed directly on a bulk semiconductor substrate and the second of two semiconductor orientations is disposed either on the substrate ( FIGS. 1A and 1C ), partially insulated from the substrate by a thin BOX layer ( FIG. 1E ), or fully insulated from the substrate by a thick BOX layer ( FIGS. 1B and 1D );
FIGS. 2A-2B show, in cross section view, prior art examples of how the hybrid-orientation substrate structure of FIG. 1B might form the basis of integrated circuits comprising at least one pFET on a 110-oriented single crystal Si region and at least one NFET on a 100-oriented single crystal Si region;
FIGS. 3A-3I show, in cross section view, the steps of the basic prior art method used to form the structures of FIGS. 1A-1E , illustrated for the case of FIG. 1B ;
FIG. 4 shows, in cross section view, a prior art example of a planar hybrid-orientation semiconductor substrate structure wherein both of two differently oriented single crystal Si regions are disposed on buried insulator layers;
FIGS. 5A-5B show, in cross section view, two preferred SOI embodiments of the hybrid-orientation substrates of the present invention;
FIG. 6 shows, in cross section view, how a hybrid-orientation substrate structure of the present invention can be used to form the basis of an integrated circuit comprising at least one pFET on a (110) Si crystallographic plane and at least one NFET on a (100) Si crystallographic plane.
FIGS. 7A-7G show, in cross section view, the basic steps underlying the methods of the present invention, illustrated for the case of upper layer amorphization and lower layer templating;
FIGS. 8A-8G show, in cross section view, a first preferred method to produce the structure of FIG. 5A of the present invention;
FIG. 9A-9F show, in cross section view, a second preferred method to produce the structure of FIG. 5B of the present invention; and
FIGS. 10A-10I show, in cross section view, different embodiments of the hybrid-orientation substrates that may be produced by the methods of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention, which provides planar hybrid-orientation SOI substrate structures and methods of fabricating the same, will now be described in greater detail by referring to the drawings that accompany the present application.
FIGS. 5A-5B show, in cross section view, two preferred embodiments of hybrid-orientation substrates that can be fabricated by the methods of the present invention. Hybrid-orientation substrate 450 of FIG. 5A and hybrid-orientation substrate 460 of FIG. 5B both comprise first single crystal semiconductor regions 470 with a first orientation, and second single crystal semiconductor regions 480 with a second orientation different from the first orientation. Semiconductor regions 470 and 480 have approximately the same thickness and are disposed on the same BOX layer 490 . The term “BOX” denotes a buried oxide region. Although this terminology is specifically used here, the present invention is not limited to merely buried oxides. Instead, various insulating layers can be used; the various insulating layers are described in greater detail hereinbelow.
Semiconductor regions 470 and 480 are separated by dielectric trench isolation regions 500 , which are shown as having the same depth and stopping on BOX layer 490 . However, in some embodiments of the present invention, trench isolation regions 500 may be shallower (so as not to reach BOX layer 490 ), deeper (so as to extend past BOX layer 490 ), or of non-equal depths, as desired. The structures of FIGS. 5A and 5B differ from each other only in the particulars of substrates 510 and 520 . Substrate 510 in FIG. 5A is a semiconductor having an epitaxial relationship to single crystal semiconductor region 480 , whereas substrate 520 in FIG. 5B has no particular restrictions other than being compatible with whatever subsequent processing it will be subjected to.
The hybrid-orientation substrate structures of FIGS. 5A-5B may be incorporated as the substrates for integrated circuits comprising at least one pFET on a (110) crystallographic plane and at least one nFET on a (100) crystallographic plane. FIG. 6 illustrates an exemplary integrated circuit on a Si version of the hybrid-orientation substrate structure of FIG. 5B , in cross section view. Substrate 520 has single crystal 110-oriented Si regions 530 and single crystal 100-oriented Si regions 540 , separated by isolation regions 500 on BOX layer 490 . pFET devices 170 are disposed on 110-oriented regions 530 and NFET devices 180 are disposed on 100-oriented regions 540 . For clarity, dopings are not shown.
The FETs shown in FIG. 6 can be fabricated on the structure shown in FIG. 5A using techniques that are well known to those skilled in the art. In some embodiments, the 110 and 100 crystal orientations of layers 540 and 530 are reversed. In that embodiment, the pFET devices 170 would still be fabricated atop the 110-oriented regions and the NFET devices 180 would be fabricated atop the 100-oriented surface.
The present invention also provides new methods for forming planar hybrid-orientation semiconductor substrate structures. Common to all methods are three basic steps, by which the orientation of selected semiconductor regions may be changed from an original orientation to a desired orientation:
forming a bilayer template layer stack comprising a first, lower single crystal semiconductor layer (or substrate) having a first orientation and a second, upper (typically bonded) single crystal semiconductor layer having a second orientation different from the first;
amorphizing one of the layers of the bilayer template stack in selected areas (by ion implantation through a mask, for example) to form localized amorphized regions; and
recrystallizing the localized amorphized regions using the non-amorphized layer of the stack as a template, thereby changing the orientation in the localized amorphized regions from an original orientation to a desired orientation.
These steps are illustrated in FIGS. 7A-7D for the case of upper layer amorphization and bottom layer templating. Although this embodiment is shown, the present invention also contemplates methods in which the bottom layer is amorphized and recrystallization is templated from the top layer.
FIG. 7A shows initial SOI substrate 580 comprising base substrate 520 , BOX layer 490 , and single crystal SOI layer 590 with a first orientation. SOI layer 590 may be formed by bonding or by any other method known to the art. FIG. 7B shows bilayer template stack 600 comprising SOI layer 590 as a lower template layer with a first orientation and single crystal semiconductor layer 610 as an upper template layer with a second orientation different from the first orientation. Layer 610 would typically be formed by bonding. FIG. 7C shows the structure of FIG. 7B after ion bombardment 620 in selected areas creates localized amorphized regions 630 . Localized amorphized regions 630 extend from the top surface of upper template layer 610 down to interface 640 , located within lower template layer 590 . Selected area ion bombardment 620 would typically be effected by blanket ion bombardment in combination with a patterned mask. FIG. 7D shows the structure of FIG. 7C after localized amorphized regions 630 have been recrystallized (starting at interface 640 , using lower layer 590 as a template) to form single crystal semiconductor region 650 . Non-amorphized upper template layer regions 610 ′ (with the second crystal orientation) and recrystallized region 650 (with the first crystal orientation) now comprise planar hybrid-orientation substrate 650 with surface A-B comprising at least two clearly defined single-crystal semiconductor regions with different surface orientations.
To minimize the possibility of lateral templating, the sides of the region(s) 630 selected for amorphization and templated recrystallization would typically be at least partially isolated from adjacent crystalline regions, for example, by trenches. The trenches may be formed and filled before amorphization, formed and filled between amorphization and recrystallization, or formed after amorphization and filled after recrystallization. Trench formation would typically be effected by a process such as reactive ion etching (RIE) through a mask.
FIGS. 7E-7G show examples of three geometries for isolation trenches. In FIG. 7E , isolation trenches 660 extend through the upper template layer, but do not extend past the amorphization depth. In this case, some templating from side interfaces 670 may occur. In FIG. 7F , isolation trenches 680 extend past the amorphization depth, but not all the way to BOX layer 490 , and in FIG. 7G , isolation trenches 690 extend all the way to BOX layer 490 . However, isolation trenches may not be necessary if the recrystallization rate of the desired crystal orientation is much faster than recrystallization templated from competing undesired crystal orientations. For example, the recrystallization rates of Si-implant-amorphized single crystal Si samples has been reported to be three times faster for 100-oriented Si than for 110-oriented Si [see, for example, L. Csepregi et al., J. Appl. Phys. 49 3096 (1978)].
The fact that different semiconductor orientations can differ in their recrystallization rates should also be considered when designing the template layer stacks and process flows. The layer of a bilayer template stack having the slower-growing orientation would preferably be the one that is amorphized, whereas the layer with the faster-growing orientation would preferably be the one from which the recrystallization is templated.
In one embodiment of the invention, shown in FIGS. 8A-8G , the basic steps of FIGS. 7A-7D are incorporated into a method for forming a planar hybrid-orientation SiOI substrate structure similar to structure 450 of FIG. 5A . For simplicity, isolation trenches are not shown. FIG. 8A shows 100-oriented Si substrate 700 comprising the first, lower layer of the template stack; FIG. 8B shows the substrate 700 after addition of 110-oriented Si layer 710 comprising the second, upper layer of the template stack. Layer 710 would typically be formed by bonding.
FIG. 8C shows the structure of FIG. 8B being subjected to ion bombardment 720 in selected areas to create the structure of FIG. 8D with localized amorphized regions 730 extending from the top surface of template layer 710 to a depth ending in substrate 700 . FIG. 8E shows the structure of FIG. 8D after localized amorphized regions 730 have been recrystallized (using 100-oriented Si substrate 700 as a template) to form single crystal 100-oriented Si region(s) 740 . Non-amorphized 110-oriented Si regions 710 ′ and recrystallized 100-oriented Si region(s) 740 now comprise bulk planar hybrid-orientation substrate 750 with surface A-B comprising at least two clearly defined single-crystal semiconductor regions with different surface orientations.
A SIMOX process is then used to create a BOX layer, as shown in FIGS. 8F-8G . FIG. 8F shows the structure of FIG. 8E being exposed to blanket oxygen ion implantation 760 used to create buried O-rich layer 770 . O-rich layer 770 preferably contains the original interface between layers 700 and 710 , and is converted into BOX layer 780 of FIG. 8G by the appropriate annealing steps.
In another embodiment of the present invention, shown in FIGS. 9A-9F , the basic steps of FIGS. 7A-7D are incorporated into yet another method to form a planar hybrid-orientation SiOI substrate structure similar to structure 460 of FIG. 5B . Specifically, FIG. 9A shows initial SiOI substrate 800 comprising base substrate 520 , BOX layer 490 , and 110-oriented single crystal Si layer 810 . Si layer 810 may be formed by bonding or by any other method known to the art. FIG. 9B shows bilayer template stack 820 comprising 110-oriented Si layer 810 as a lower template layer and single crystal 100-oriented Si layer 830 as an upper template layer. Layer 830 would typically be formed by bonding. FIG. 9C shows the structure of FIG. 9B being subjected to ion bombardment 840 in selected areas to create the structure of FIG. 9D with buried localized amorphized regions 850 . Localized amorphized regions 850 extend from BOX layer 490 through lower template layer 810 and partially into upper template layer 830 . As mentioned above, the areas selected for amorphization and templated recrystallization would typically be isolated from adjacent crystalline regions by trenches (not shown) to minimize the possibility of lateral templating. FIG. 9E shows the structure of FIG. 9D after localized amorphized regions 850 have been recrystallized, using upper template layer 810 as a template, to form 100-oriented single crystal Si regions 860 . Upper template layer 810 is then removed by a process such as polishing (or oxidation followed by wet etchback) to leave coplanar 110-oriented single-crystal Si regions 810 ′ and 100-oriented single-crystal Si regions 860 disposed on common BOX layer 490 .
It should be noted that the method of FIGS. 8A-8G may equally well be employed with the orientations of substrate 700 and upper template layer 710 reversed, i.e., with substrate 700 comprising a 110-oriented Si wafer instead of a 100-oriented Si wafer, and upper template layer 710 comprising a single crystal layer of 100-oriented Si instead of a single crystal layer of 110-oriented Si. Likewise, the method of FIGS. 9A-9F may be employed with the orientations of lower template layer 810 and upper template layer 830 reversed, i.e., with lower template layer 810 being 100-oriented Si instead of 110-oriented Si and upper template layer 830 being 110-oriented Si instead of 100-oriented Si. More generally, the structures and methods of the present invention may be employed using semiconductors other than Si, as will be described in more detail below.
FIGS. 10A-10I show, in cross section view, different embodiments of the hybrid-orientation substrates that may be produced by the methods of the present invention. FIG. 10A shows “bulk” planar hybrid-orientation semiconductor substrate structure 900 comprising first single crystal semiconductor regions 910 with a first orientation, and second single crystal semiconductor regions 920 with a second orientation different from the first orientation, but identical to the orientation of substrate 930 . Planar hybrid-orientation semiconductor substrate structure 940 of FIG. 10B is similar to structure 900 of FIG. 10A , but has trench isolation regions 950 separating single crystal semiconductor regions 910 and 920 .
Planar hybrid-orientation semiconductor substrate structure 960 of FIG. 10C is similar to structure 900 of FIG. 10A . However, substrate 930 has been replaced with substrate 980 , which may or not be epitaxially related to semiconductor region 920 . Structure 960 also comprises BOX layer 970 under semiconductor regions 910 and 920 , and residuals 990 of second semiconductor material with the second orientation remaining under first semiconductor regions 910 . Planar hybrid-orientation semiconductor substrate structure 1000 of FIG. 10D is similar to structure 960 of FIG. 10C , except that semiconductor region 920 is epitaxial related to semiconductor substrate 930 , and BOX layer 970 is located above interface 1010 between first single crystal semiconductor regions 910 and substrate 930 .
Planar hybrid-orientation semiconductor substrate structures 1020 and 1030 of FIGS. 10E-10F are identical to structures 1000 and 940 of FIGS. 10A-10B , except that semiconductor substrate 930 has been replaced by insulating substrate 1040 .
Planar hybrid-orientation semiconductor substrate structures 1050 and 1060 of FIGS. 10G-10H are similar to structure 960 of FIG. 10C , but have trench isolation regions 950 . In structure 1050 of FIG. 10G , trench isolation regions 950 extend below interface 1070 between first single crystal semiconductor regions 910 and residuals 990 , but do not reach BOX layer 970 . In structure 1060 of FIG. 10H , trench isolation regions 950 extend to BOX layer 970 .
Planar hybrid-orientation semiconductor substrate structure 1080 of FIG. 10I comprises three differently oriented single crystal semiconductor regions 910 , 920 , and 1090 , separated by trench isolation regions 950 extending to BOX layer 970 . Planar hybrid-orientation semiconductor substrate structures with three or more surface orientations may be produced by the localized amorphization and recrystallization methods of this invention by using a multilayer template stack instead of a bilayer template stack.
Structures like those of FIGS. 5A-5B and FIGS. 10A-10I may be produced by using various permutations of the basic steps of the invention with or without additional steps. For example, a planar hybrid-orientation structure resembling 460 of FIG. 5B may be produced from the structure of FIG. 10H by the additional steps of amorphizing residuals 990 of second semiconductor material 920 and recrystallizing the amorphized regions using single crystal region 910 as a template.
The semiconductor substrates and single crystal semiconductor regions of the present invention may be selected from a wide range of semiconductor materials. For example, substrates 510 , 520 , 700 , 930 and 980 , and differently oriented first and second semiconductor regions 470 , 610 ′, 910 , and 480 , 650 , and 920 may be selected from the group including Si, SiC, SiGe, SiGeC, Ge alloys, Ge, C, GaAs, InAs, InP as well as other III-V or II-VI compound semiconductors. Layered combinations or alloys of the aforementioned semiconductor materials (for example, Si layers on SiGe), with or without one or more dopants, are also contemplated herein. First and second semiconductor regions may be strained, unstrained, or a combination of strained and unstrained layers can be used. The crystallographic orientations would typically be selected from the group including (110), (111), and (100).
The thickness of first and second single crystal semiconductor regions 470 , 610 ′, 910 , and 480 , 650 , and 920 is typically from about 1 to about 500 nm, with a thickness from about 10 to about 100 nm being more typical. The thickness of substrates 510 , 520 , 700 , 930 , and 980 would typically be between 5 and 1000 μm, and most typically be about 600 μm.
BOX layers and insulating substrates 1040 may be selected from a wide range of dielectric materials, including, but not limited to the group including SiO 2 , crystalline SiO 2 , SiO 2 containing nitrogen or other elements, silicon nitrides, metal oxides (e.g., Al 2 O 3 ), insulating metal nitrides (e.g., AlN), highly thermally conductive materials such as crystalline diamond. BOX thicknesses may range from about 2 nm to about 500 nm, with preferable thicknesses typically being in the range from about 50 to about 150 nm.
Bonding methods for forming the template stack may include any methods known to those skilled in the art (see, for example, Q. Y. Tong et al. [in Semiconductor Wafer Bonding: Science and Technology (John Wiley, 1998)] and co-pending and co-assigned U.S. application Ser. No. 10/696,634, filed Oct. 29, 2003, and co-pending and co-assigned U.S. application Ser. No. 10/250,241, filed Jun. 17, 2003). The contents of each of the above mentioned co-assigned U.S. Applications are incorporated herein by reference.
Differently oriented semiconductor surfaces to be bonded are preferably hydrophobic (rather than hydrophilic) for the cleanest possible interfaces, since impurities in the amorphized regions will typically impede the progress of the recrystallization. However, very thin oxides at the bonded interface may be tolerable if the oxide can be made to assume a discontinuous, islanded morphology by suitable annealing (see, for example, P. McCann et al. [(“An investigation into interfacial oxide in direct silicon bonding,” 6th Int. Symp. on Semiconductor Wafer Bonding, San Francisco, Sep. 2-7, 2001]). Wafer separation/removal after bonding may be accomplished by grinding or etching the wafer away (preferably making use of an etch stop layer), or by making use of a mechanically weak interface layer created at earlier steps in processing. Examples of mechanically weak interface layers include porous Si (see, for example, Epitaxial Layer Transfer (ELTRAN) described by K. Sakaguchi et al. in Solid State Technology, June 2000] and ion-implanted H-containing bubbles (see, for example, Smart Cut process, described in U.S. Pat. No. 5,374,564 by M. Bruel, which issued Dec. 20, 1994, and U.S. Pat. No. 5,882,987 by K. V. Srikrishnan, which issued Mar. 16, 1999).
Amorphization would typically be effected by ion implantation. The optimum ion implantation conditions will depend on the materials of the template layers, the thickness of the template layers, and position (upper or lower) of the stack layer being amorphized. Any ion species known to those skilled in the art may be used, including but not limited to: Si, Ge, Ar, C, O, N, H, He, Kr, Xe, P, B, As, etc. Ions for the amorphization are preferably Si or Ge. Lighter ions such as H and He are typically less effective at amorphization. Ion implantation may be performed at temperatures ranging from cryogenic to several hundred ° C. above nominal room temperature. By “nominal room temperature” it is meant a temperature from about 20° to about 40° C. Regions not being amorphized would typically be protected from ion implantation by a patterned mask (for example, patterned photoresist for a room temperature implantation process). Implants may be performed with or without “screen oxide” layers and may be performed with multiple implants at different energies if a sufficiently uniformly amorphized region cannot be easily achieved with a single implant. The required implant dose depends on the implanting species, the semiconductor being implanted, and the thickness of the layer needing to be amorphized. Si implanted at cryogenic temperatures at 50, 100, 150, and 200 keV with a total dose of 6E15/cm 2 was found to be sufficient to amorphize the top 400 nm of 100-oriented and 110-oriented Si (see, for example, L. Csepregi et al.). However, much lower doses (for example, 5E14/cm 2 at 40 keV) can amorphize Si when the implanted ion is Ge and surface region to be amorphized is thinner than 50-100 nm.
Recrystallization of localized amorphous regions 630 , 730 , and 850 is typically effected by annealing at temperatures from about 200° to about 1300° C., preferably from about 400° to about 900° C., and more preferably from about 400° and 600° C., for a time period sufficient to bring about the desired recrystallization. This time period will depend on the orientation of the template layer, on the thickness of the amorphized region to be recrystallized, on the presence of implanted and other impurities in the amorphized layer, and possibly on the sharpness of the interface between the implanted and unimplanted regions. Annealing may be performed in a furnace or by rapid thermal annealing. In other embodiments, annealing may be performed using a laser anneal or a spike anneal. The annealing ambient would typically be selected from the group of gases including N 2 , Ar, He, H 2 and mixtures of these gases.
When a buried insulating is created in the structure following the recrystallizing step, any conventional ion implant step and annealing step that can be used in forming a buried insulating layer can be employed. For example, any conventional SIMOX process can be used in producing a buried oxide layer in the structures shown in FIGS. 8F-8G .
Several embodiments of the present invention, together with modifications thereof, have been described in detail herein and illustrated in the accompanying drawings, it will be evident that various further modifications are possible without departing from the scope of the invention. In particular, it should be emphasized that while most of the substrate structures, circuits, and methods of this invention have been illustrated for the case of a small number of single crystal regions having two different orientations, the invention applies equally well to methods for providing and structures comprising large pluralities of such single crystal regions. Furthermore, the hybrid-orientation substrates of the invention may incorporate additional overlayers (such as epitaxially grown semiconductors or additional bonded layers), removal or etchback of certain surface features (for example, recessing one or more of the single crystal semiconductor regions or trench isolations), and/or specialized doping profiles, if such substrate features are desired for the subsequently fabricated devices. Nothing in the above specification is intended to limit the invention more narrowly than the appended claims. The examples given are intended only to be illustrative rather than exclusive.
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A method utilizing localized amorphization and recrystallization of stacked template layers is provided for making a planar substrate having semiconductor layers of different crystallographic orientations. Also provided are hybrid-orientation semiconductor substrate structures built with the methods of the invention, as well as such structures integrated with various CMOS circuits comprising at least two semiconductor devices disposed on different surface orientations for enhanced device performance.
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FIELD OF THE INVENTION
This invention relates to working vehicles such as agricultural combines and the like provided with a crawler respectively on the left and the right sides, operating section, driving means with belt and a hulling machine with a grain sorting device.
BACKGROUND OF THE INVENTION
Tracked agricultural combines are a common type of working vehicle. In these prior combines, left and right crawlers or track assemblies are respectively driven by left and right hydrostatic transmission device (hereinafter abbreviated to HST) and steering is conducted by using independent left and right operating levers linked to a trunnion lever of an associated HST. This form of control causes these combines to be difficult to operate smoothly. They are poor in maneuverability because speed changing operations and turning operations have to be made by using the two levers.
Under the circumstances disclosed in Japanese patent publication No. sho 40-18576, speed changing means such as acceleration pedal and turning means such as steering wheel are respectively linked to each trunnion lever of each HST on the left and the right and forward/backward movement is made by using speed changing means and left/right turning movement is made by using turning means in order to conduct operation smoothly.
However, in the conventional art, many kinds of cams are needed to link the speed changing means and the turning means to each gear lever on both sides and accordingly many kinds of bevel gears are needed to couple various means with the cams.
OBJECTIVES AND SUMMARY OF THE INVENTION
Meanwhile, according to this invention it becomes possible to produce a working vehicle comprising: a gear shaft which is put in a gear box 28 and rotates in association with change of gear lever 35; left and right sliders 58, 59 which are designed to slide on gear shaft 33 along its axial line; left and right speed changing means 26, 27 which are linked to said left and right sliders 58, 59 and used to drive left and right crawlers 2; steering wheel 32 which is coupled to said gearbox 28 so as to freely rotate the main slider 53 which is slid by turning said steering wheel and thereby makes said sliders 58, 59 slide, characterized in that said gear shaft 33 and said left and right sliders 58, 59 are moved in one body by manipulating said gear lever 35 in order that said speed changing means 26, 27 may be switched to direct to the same direction at the same time and make said crawlers go straight forward or backward and that either one of said left and right sliders 58, 59 slid by said main slider 53 is put in such position by turning said handle 32 as to stop or move said one of said crawlers in the reverse direction to turn said working vehicle. Because of this invention, the left and the right sliders 58, 59 and the main slider 53 can be incorporated around the gear shaft 33 in a compact manner and the gear lever 35 and the steering wheel 32 can functionally be arranged around the gear shaft 33 and thereby the structure of the operating section A of FIG. 4 can be simplified and the production cost can be easily reduced.
Also in the conventional hulling machine driving systems, the tension roller clutch for applying tension to the belt with a lever to transmit the engine's driving power to the hulling section is used as the clutch of the hulling section. However, in such tension roller clutches, because the lever for switching the clutch is linked to clutch arm with wire, the operating system inevitably becomes much more complex, especially when the clutch of this type is used in a large agricultural machine such as combine. From this standpoint, it seems better to use a clutch motor in place of the aforementioned lever to switch the tension roller clutch. However, when the clutch motor is used at high speed, a large impact tends to be applied on the belt and when it is used at slow speed, maneuverability tends to be poor.
On the contrary, the combine of this invention is comprised of an engine 16 mounted on the machine floor, a belt for transmitting the driving force of said engine to the working section and a tension roller clutch 145 provided approximately in the middle point of the belt. A clutch motor 150 and control means for said tension roller clutch 145 makes the action of said tension roller clutch 145 caused by the input of said clutch motor 150 fast before said tension roller clutch touches said belt and makes said action gradually slow after said tension roller clutch touches said belt. By this device, maneuverability is improved and tension suddenly applied on the belt by sudden switching-on of the clutch motor can be avoided and thereby incidents of its breaking can be minimized to prolong the life of the belt.
Also, as disclosed in Japanese utility model application laid-open publication No. hei 3-108332, in the hulling section, the front grain sorting plate and the rear grain sorting plate are conventionally put one on the other in order that grains may fall through both plates. Therefore, their total thickness is great. Moreover, the difference in each of their weight tends to be great, whereby the difference in momentum between them also tends to be great. For this reason, the structure of vibration control equipment and their driving means can hardly be simplified.
However, the combine according to this invention, in which hulling machine 4, provided with cylinder 5 and grain sorter 7, is mounted on the vehicle floor and thereby substantially forms a combine characterized in that said grain sorter 7 is provided with front grain sorting plate 169 and rear grain sorting plate 170 which allow grains to fall for screening and said rear grain sorting plate 170 is provided with first grain flowing plate 179 to take out screened grains. Therefore, the total length of the two sorting plates can be reduced; the difference in each of their weight can also be reduced and so the difference in momentum between their swinging movement can be reduced. On this account, the structure of vibration control equipment and their driving means can be simplified.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of this invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a side view of the combine.
FIG. 2 is a plan of the combine.
FIG. 3 is a rear view of operating section of the combine.
FIG. 4 is a partially cutaway rear view of the operating section.
FIG. 5 is a cross-sectional bottom view of the operating section.
FIG. 6 is a cross-sectional side view of the operating section taken from the left.
FIG. 7 is another cross-sectional side view of the operating section taken from the left.
FIG. 8 is an illustration showing gear lever in the neutral position and handle in the neutral position too. (At this time the combine is still.)
FIG. 9 is an illustration showing the gear lever in the forwarding position and the handle in the neutral position. (At this time the combine goes straight forward.)
FIG. 10 is an illustration showing the gear lever in the forwarding position and the handle turned clockwise. (At this time the combine turns to the right.)
FIG. 11 is an illustration showing the gear lever in the forwarding position and the handle turned more clockwise. (At this time the combine spins or sharply turns to the right.)
FIG. 12 is a perspective view of the operating section.
FIG. 13 is a rear view of driving system for hulling machine.
FIG. 14 is a cross-sectional view of engine section.
FIG. 15 is a rear view of clutch section.
FIG. 16 is a side view of the clutch section.
FIG. 17 is a plan of the clutch section.
FIG. 18 is a partially enlarged rear view of the clutch section.
FIG. 19 is an illustration showing the whole engine driving system.
FIG. 20 is a side view of the hulling section.
FIG. 21 is a plan of the hulling section.
FIG. 22 is an elevation of the hulling section.
FIG. 23 is a side view of grain sorting machine.
FIG. 24 is an enlarged side view of swinging grain sorting plates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention will be described in more detail according to the attached drawings. In FIGS. 1 and 2, vehicle floor 1 is mounted on frame 3 which supports two crawlers or propulsion tracks 2, one on the left and one on the right side of the agricultural combine. A hulling machine 4 provided with a screw type transport cylinder 5, a treating drum 6 and a grain sorter 7 is mounted on the vehicle floor 1. Grain tank 8 is designed to hold grains taken out from the hulling machine 4 by way of grain lifting pipe 9. Reaper 10 is designed to move up and down by means of hydraulic pressure cylinder 11 located below in front of the hulling machine 4. The operators' cabin 12 is provided with seat 13 and an operation panel 14 is located before the grain tank 8. Engine cover 15 enclosing engine 16 is located behind the grain tank 8. Auger 17 is for taking out grains from the grain tank 8.
The reaper 10 is provided with a couple of headers 18 to push their front end into yet unreaped plants and feeder house 19 is located behind the middle of the two headers to feed reaped plants to the hulling machine 4. Provided between the headers 18 are reel 20 for taking in unreaped plants, first blade 21 and second blade 22, each capable of alternating motion and auger 23 for taking in reaped plants. Reaped plants taken from the headers 18 are carried to the hulling machine 4 by means of chain conveyer 24 inside the feeder house 19.
Provided on the right side of the hulling machine is a second return pipe 25 to get yet unhulled grains back to the hulling machine 4 through the treating drum 6 in order to get them rehulled and resorted.
FIG. 3 is an outline of the operating system relating to this invention. The operating system controls the position of right tilting plate 26 and left tilting plate 27 which respectively controls an hydraulic pressure motor provided on each HST 120 that drives the crawlers 2 on both sides of the combine, whereby the combine can be moved forward and backward or turned to the right or the left, gently or sharply according to the circumstances.
As shown in FIGS. 3 and 4, in the operating system an operating gear is enclosed in gearbox 28 of which the shape is long in the lateral direction of the combine. In the middle part of top plate 29 of the gearbox 28, a hollow column 30 to house a steering wheel shaft 31 is erected. Provided to on top of the steering wheel shaft 31 is a round steering wheel 32. A main gear shaft 33 is put horizontally in the gearbox 28. To the right outside end 34 of the gear shaft 33, the lower end of gear lever 35 (power transmission control) is fixed by means of lever stay 36. In the figures, 37 denotes foot, 38 denotes wire stay, 39 denotes gear case, 40 denotes brackets for the holding gear case, 41 denotes securing bolts for the gear case, 42 denotes lever guide for the gear lever and 43 denotes the floor.
As shown in FIGS. 5 and 6, base 45 which receives the steering wheel shaft 31 is rotatably placed between the top plate 29 and bottom plate 44. A pinion gear 46 is provided around the base 45 which is supported by bearing 47. Also, as shown in FIGS. 4 to 6, a sliding shaft 50 spanning left and right side walls 48, 49 of the gearbox 28 is placed parallel to the gear shaft 33 at a certain distance thereto. The shape of the cross section of the gear shaft 33 is generally triangular. Bearings 52 support and let the gear shaft rotate freely.
As shown in FIGS. 5 to 7, a main slider 53 is mounted on the sliding shaft 50 in such a way as to freely move to the right and to the left. The main slider 53 is composed of base 54 freely slidable on the sliding shaft 50 and actuator 55 positioned just below the gear shaft 33. A rack 56 extending in the axial direction of the gear shaft 33 is provided under the actuator 55 and allowed to engage with the pinion gear 46. In the figure, 57 denotes the rack guide.
By the above mentioned structure, the main slider 53 is moved to the right or the left on the sliding shaft 50 by means of the rack 56 and the pinion gear 46 which is attached to the base 45 of the steering wheel shaft 31, when the steering wheel 32 is turned to the right (clockwise) or to the left (counter-clockwise).
Two sliders 58 and 59 are slidably mounted on the sliding shaft 50 and the main gear shaft 33, one on the right side and another on the left side thereof. Springs 60 and 61 are attached to the outside of the sliders 58, 59 respectively in order to get the sliders 58, 59 back to the original neutral position. On the other hand, an inverted U shaped stopper 62 is provided in the center of the top plate 29 of the gearbox 28 so that the sliders 58, 59 can be stopped at the neutral position by the stopper. Left arm holder 63 is provided on the right end of the left slider 58 so as to freely rotate thereon, as shown in FIGS. 4 to 7. Moreover, a stopper 64 for preventing the left arm holder 63 from rotating counter-clockwise is extended from the front side of the left arm holder 63 so that the stopper 64 can slide on the sliding shaft 50 freely. A left guide supporting arm 65 is extended down and backward from the rear side of the left arm holder 63. A boss 66 is attached to the end of the arm 65 and a pivot pin 67, the axis of which extends in the longitudinal direction, is horizontally inserted in the boss 66 so as to freely rotate. The rear end of the pivot pin 67 is fixed to the center of the front side of the left guide member 68 which extends in the lateral direction and of which the rear side opens backward. A bushing 69 supports the left arm holder 63.
As shown in FIGS. 4 to 6, a left swinging arm 70 is extended from on the left end of the left slider 58. The upper end of the left link 71, which can be freely extended and contracted, is connected to the end of the left swinging arm 70 by means of connecting pin 72. The lower end of the left link 71 and the front side of the left guide member 68 are connected by means of connecting pin 73.
According to the above mentioned structure, the left guide member 68 is moved with the left slider 58 in one body on the sliding shaft 50 and the main gear shaft 33 in association with the sliding movement of the main slider 53. Also, the left guide member 68 is designed to swing up and down around pivot pin 74 together with the left slider 58 which is rotated in association with the rotating movement of the main gear shaft 33 caused by the gear lever 35. In FIG. 6, W shows the rotation range of the main gear shaft 33 and within the range the end of the left guide 68 swings up and down.
As shown in FIGS. 4 to 7, the left rotator 75 is engaged with the left guide member 68 in such a way as to freely rotate and slide to the right and left along the left guide member. The left rotator 75 and outside end of left rotator supporting arm 76 is joined by means of bearing shaft 77 and the inside end of the arm 76 is joined to the rear wall 79 of the gearbox 28 by means of boss 80 so that the arm 76 can pivot and freely swing up and down with arm bearing shaft 81. Outside the gearbox 28, the end of the arm bearing shaft 81 is joined to the left end of the left tilting plate actuating arm 82 by bolt 83 and the right end of the arm 82 is connected to the right tilting plate 27, which controls hydraulic pressure motor, by means of the left connecting wire 84. In FIG. 5, 85 denotes the stopper for the left rotator 75 and 86 denotes the wire connecting pin.
By this structure, when the left guide member 68 slides to the right or the left keeping its tilting position, the left rotator supporting arm 76 is swung by means of the left rotator 75. At this time, the left tilting plate actuating arm 82 swings up and down oppositely to the swinging movement of the rotator supporting arm 76. This moves the right tilting plate 27 by way of the left connecting wire 84 to control the hydraulic pressure motor.
The above description has been made in relation to a series of members from the left slider 58 to the right tilting plate 27. A similar description can also be made in relation to a series of members from right slider 59 to the left tilting plate 26 because both series of members are made in a symmetrical relationship. However, by way of precaution, the names of the corresponding other members are listed as follows: 87 denotes the right arm holder, 88 the stopper for the right arm holder, 89 the right guide supporting arm, 90 the right boss, 91 the pivot pin, 92 the right guide, 93 the stopper for the right rotator, 94 the right swinging arm, 95 the right link, 97 the connecting pin, 98 the right rotator, 99 the right rotator supporting arm, 100 the bearing shaft, 101 the boss, 102 the arm bearing shaft, 103 the right tilting plate actuating arm, 104 the actuating arm fixing bolt, 105 the right connecting wire, 106 the bushing and 107 the wire connecting pin.
Now a sequence of motions caused by the above mentioned members will be described in reference with FIG. 4 and FIGS. 8 to 11. As shown in FIG. 8, the left and right guides 68, 92, the left and right rotator supporting arms 76, 99 and the left and right tilting plate actuating arms 82, 103 generally keep in the horizontal position as long as the gear lever 35 and the steering wheel 32 are put in the neutral position.
Meanwhile, when the gear lever 35 is put in the forwarding position, the main gear shaft 33 begins to rotate by which the left and right sliders are slid, the left and right swinging arms and the left and right links are moved and the left and right guides 68, 92 are turned around the pivot pins 67, 91. And thereby the left and right rotator supporting arms 76, 99, the arm bearing shafts 81, 102 and the left and right tilting plate actuating arms 82, 103 are put in the tilting position as shown in FIG. 9.
In this case, the tilting angle of the left tilting plate 26 is equal to that of the right tilting plate 27 and so the left and right crawlers 2, turn forward at the same speed; thus, the combine goes straight forward.
However, when the handle is turned clockwise, the steering wheel shaft 31 is rotated accordingly and the rack 56 coupled with the pinion 46 is moved to the left, by which the main slider 53 pushes and makes the left slider 58 slide to the left.
As a result, the left guide 68 coupled with the left slider 58 is slid to the left with its tilting position unchanged and the left rotator 75 is slid generally to the center of the left guide as shown in FIG. 10, by which the left rotator supporting arm 76 and the right tilting plate actuating arm 82 take approximately horizontal positions and the right tilting plate 27 takes an approximately neutral position.
In this case, the speed of the right crawler 2 is decreased or even reduced to zero, while the left crawler 2 keeps advancing as it is. As a result, the combine turns to the right gently.
When the steering wheel 32 is turned more clockwise, the left guide 68 is slid more to the left with its tilting position unchanged and the left rotator 75 having been generally in the middle of the left guide 68 is moved to the right end of the left guide as shown in FIG. 11, by which the left ends of the left rotator supporting arm 76 and the right tilting plate actuating arm 82 are lowered and the right ends are raised. As a result, the right tilting plate 27 is tilted so as to cause the associated crawler to go backward.
In this case, the right crawler 2 turns back, while the left crawler 2 turns fore. Thus, the combine can spin or turn clockwise sharply.
The combine can be spun or turned counter clockwise by turning the steering wheel 32 in the direction opposite the above. Also, regardless of the steering wheel position, the combine can be stopped by getting the gear lever 35 back to the neutral position or moved backward by putting the gear lever in the retreating position or turned to the right or the left while being moved backward by using both the steering wheel and the gear lever. By such excellent maneuverability of the combine many kinds of cropping jobs can be carried out in an efficient manner.
That is, because the combine can be turned freely regardless of the gear lever position or stopped regardless of the steering wheel position, not only is maneuverability easy but misoperation can be avoided and safety of workers in jobs is assured, by which cropping jobs can be made efficiently.
In this example, the sliders 58, 59 are arranged in the left and right of the gearbox 28; however, as a matter of course they can be arranged above and below or obliquely to each other according to the circumstances.
As shown in FIGS. 13 to 19, engine 16 for driving the hulling machine 4, radiator 108 for cooling the engine and sirocco fan 109 for cooling the radiator 108 are arranged separately above and below in the hulling section. Output shaft 111 on the flywheel 110 side of the engine 16 is connected to counter shaft 113 supported by shaft bearing 112 on the right side of the engine 16 by a universal joint 114. Pulleys 115, 116, 117, each fixed to the counter shaft 113, are respectively connected to input pulley 119 of the hulling machine's shaft 118, input pulley 122 of HST's shaft 121 and input pulley 125 of input shaft 124 for driving the auger 123 by using transmission belts 126, 127 and 128 in order to drive the hulling machine 4, the crawlers 2 and the grain tank 8.
The hulling machine shaft 118 and the hulling machine counter shaft 129 are connected to each other by using reduction gears 130, 131 and 132. The hulling machine counter shaft 129 is connected to gearbox shaft 137 by using pulleys 138, 139 and belt 140. The gearbox shaft 137 is connected to the cylinder shaft 133 with two stage speed change gears 134, 135 and switching gear 136, by which the cylinder 5 can be rotated in two, high/low, different speeds. Meanwhile, 141 and 142 denote first and second conveyers of the hulling machine 4, 184 denotes the grain fan and 181 denotes a prefan or an auxiliary fan of the grain fan 184.
Additionally, the tension on the transmission belt 126 connecting the counter shaft 113 and the hulling machine shaft 118 is controlled by the tension roller clutch 145. The tension roller 145, which can be mounted on or dismounted from the belt 126, is held by roller bearing shaft 148 on one upper end of tension arm 147 of which the other lower end is pivotally fixed to bearing shaft 146 on the top of the bearing shaft base 112. On the other side of the belt 126 on which tension is applied by the tension roller clutch 145, there is an electric clutch motor 150 pivotally mounted on plate 149. Shaft 154 on the top of rotating arm 152 fixed to motor shaft 151 and shaft 155 on the top of plate 153 unmovably fixed to the top of the tension roller clutch 145 are connected to each other to jointly move by using tension spring 156 and connecting rod 158 provided with guide rod 157. By this device, the tension roller clutch can be mounted on or dismounted from the belt 126 by turning the motor in right or reverse direction.
The connecting rod 158 which is laid in line with the tension spring 156 between the two shafts 154 and 155 is provided so that it comes to be generally in line with the rotating arm 152 when the tension roller clutch 145 is put on. In this device in order to prolong the belt's life, speed of the tension roller clutch from its touching the belt to its showing the maximum tension is designed to gradually slow down and action in response to on/off of the clutch is also designed to take place after a certain time interval.
The motor shaft 151 is provided with a butting piece 159 so that the piece is butted against stoppers 160, 161 mounted on the clutch motor 150 when the tension roller clutch is switched on or off, whereby the motor's position is limited. More specifically, the piece 159 is butted against the stopper 160 so that the spring 156 and the connecting rod 158 can maintain their position over the fulcrum of the motor shaft 151 when the tension roller clutch is switched on. Also the piece 159 is butted against the stopper 160 so that they can maintain their position when one side of the belt 126 to which the tension roller clutch 145 is touched is so tensed as to get the tension arm 147 back to the off-position and the other side of the belt 126 is slackened by the engine stop (this gives the cylinder 5 inertia rotation), for example, while the tension roller clutch is being switched on, whereby their position is prevented from turning over the limited range.
As described above, compared to the conventional means in which the tension roller clutch and clutch lever are connected with and operated by wire, this new system, in which the on/off switching of the tension roller clutch is conducted by the clutch motor 150, can simplify the structure of the operation section, widely reduce manipulating power and make the tension roller clutch conduct exact on/off switching.
Also in this case, abrupt on/off switching of the tension roller clutch 145 is avoided by putting a certain time interval before that switching by using the motor. That is, when the roller clutch is switched on, action before the belt is tensed by the tension roller clutch can be made to gradually slow down by the semi-circle movement of the rotating arm 152. In this way, the sudden clutch impact on the belt 126 is avoided and the belt is prevented from breaking, whereby the life of the belt can be prolonged.
As shown in FIGS. 20, 21 and 22, the screw-type cylinder 5 is comprised of cylindrical body 162, the length of which is generally equal to the length of the hulling machine 4. A spirally winding vane 163 on the outside of the cylindrical body and projection 164 for exhausting dust is provided at the rear end of the cylindrical body 162. The screw type cylinder 5 is supported by bearings with its axis laid in the longitudinal direction; its front end is an inlet communicating with the feeder house 19 and its rear end is near outlet 167 for purging dust. Provided to under the cylinder is receiving net 168 where the reaped plants taken in from the feeder house can be hulled.
The grain sorter is provided with swinging grain sorting plates 169, 170 to which swinging link 171 gives swinging movement in the longitudinal direction. Provided in the front grain sorting plate 169 is a feed pan 172 under the front part of the cylinder 5, first chaff sieve 173 to regulate the amount of falling grains, first screening net 174 under the first chaff sieve 173 and sieve line 175 connected to the rear part of the first chaff sieve 173. Provided to the rear grain sorting plate 170 is a second chaff sieve 176 under the rear part of the sieving line 175, sieve line 177 connected to the rear part of the second chaff sieve 176, returning plate 178 above the sieve line 177 and below the rear end of the receiving net 168 and first and second grain flowing plates 179, 180. The front end of the returning plate 178 is located above the front end of the sieve line and the rear end thereof is located under the rear end of the receiving net 168.
In addition to the above mentioned members: There is a fan 181 for removing dust which sends sorting air onto the feed pan 172. A grain fan 184 which sends sorting air through the first and second air ducts 182, 183 and under the first chaff sieve 173 and first sorting net 174. A first trough 185 and first conveyer 186 which receives grains from the first sorting net 174 and feeds them to the grain lifting pipe 9. A second sorting fan 187 which sends sorting air under the second chaff sieve 176 and onto the second grain flowing plate 180. A second trough 188 and second conveyer 189 which receive grains from the second flowing plate 180 and sends them to the second returning pipe 25. A third outlet 190 which is in communication with the sieve line 177 on the rear end of the rear grain sorting plate 170 in this system, where grains on the first trough 185 are sent to the grain tank 8 and returned grains on the second trough 188 are sent to the treating drum 6.
As shown in FIGS. 20, 23 and 24, fixed before the rear grain sorting plate 170 is a first grain flowing plate 179. The difference in weight between the front and the rear grain sorting plates 169, 170 is made as little as possible. The first grain flowing plate 179 is always located behind and under the rear end of the first sorting net 174. The rear end of the front grain sorting plate 169 and the front end of the rear grain sorting plate 170 are respectively joined to each end of arm 192, the center of which is held by and can freely swing around pivot 191, whereby when one grain sorting plate goes forward, another goes backward reciprocally. By this device, grains are always sent from the first sorting net 174 through the first flowing plate 179 to the first trough 185 even when the two grain sorting plates are drawn the nearest to or the farthest from each other or even when the amount of grains falling from the first sorting net 174 comes to be great. Also because the first sorting net 174 and the first grain flowing plate 179 are reciprocally moved, grains are prevented from staying on the plate 179 and this makes it possible to screen grains from dust in wet condition and eventually leads to the improvement in working efficiency.
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A tracked agricultural combine vehicle for harvesting, hulling and sorting grain includes integrated control means for left and right side propulsion track assemblies wherein individual track steering commands in the form of differential track speed control are derived from a common steering wheel input and vehicle speed is controlled by a single input means which controls the speed of both tracks.
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FIELD OF THE INVENTION
[0001] The present invention relates to water-saving devices, and particularly to a water-stop plug for adjusting water-draining of a stool, wherein in the stool of the present invention, the water supply of the water-stop plug is adjustable according to the requirement of the user so as to save supplied water.
BACKGROUND OF THE INVENTION
[0002] Stool has become a necessary device for the currently life, but generally, the water supplied to the stool is unadjustable and a large amount of water is supplied for each time the stool is used so that water is wasted. Tools are necessary for adjusting water supplied to the stool, however, this is inconvenient, and thus the user can not determine the water to flush a stool each time the stool is used.
[0003] A prior art water-stop plug is illustrated in FIG. 1. In that prior art, a linkage 12 is controlled by the handle 11 so that a chain 13 is driven to pull the cover 15 of the plug 1 to drain water. Thus, the water in the water box drains out from a draining tube 17 . A pontoon 14 is engaged with the chain 13 . By adjusting the level of the pontoon 14 , the speed of the cover 15 to cover an object is controllable so as to achieve the object of saving water. However, the disadvantage of this prior art is that adjustment of the pontoon 14 is insensitive and thus the object of saving water can not be well controlled.
SUMMARY OF THE INVENTION
[0004] Accordingly, the primary object of the present invention is to provide a water-stop plug for adjusting water-draining of a stool comprising a cover, a water-stop washer, a small washer and a plug. The water supply of the water-stop plug of a stool is adjustable according to the requirement of the user so as to save supplied water.
[0005] To achieve above objects, the present invention provides a water-stop plug for adjusting water-draining of a stool, which comprises a cover, a water-stop washer, a small washer and a plug.
[0006] The cover is a round piece with a diameter slightly larger than a diameter of the water box draining tube. A plug is coupled to the water-stop washer; one side of the cover is extended with a pair of symmetrical extending arms; a distal end of each extending arm is formed with a second notch. The water-stop washer is a round soft piece with a round hole at a center portion thereof; and the water-stop washer is mounted between the cover and the plug as a draining-preventing means. The small washer is a round hard piece with a round hole at a center portion thereof; and a plug is a hollow hemisphere. A top thereof is formed with a water inlet, and one lateral side has an air hole. A lower portion of the plug is extended with a flange.
[0007] The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a schematic view of the pontoon adjustment in the prior art.
[0009] [0009]FIG. 2 is an exploded perspective view of the present invention.
[0010] [0010]FIG. 3 is a schematic cross sectional view of the present invention.
[0011] [0011]FIG. 4 shows one operation of the present invention.
[0012] [0012]FIG. 5 shows another operation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring to the appended drawings, the water-stop plug for adjusting water-draining of a stool of the present invention is illustrated.
[0014] With reference to FIGS. 2 and 3, an exploded perspective view of the present invention and a partial schematic view of the present invention are illustrated. The present invention has a cover 22 , a water-stop washer 23 , a small washer 24 and a plug 25 .
[0015] The cover 22 is a round piece the diameter of which is slightly larger than the tube diameter of the water box draining tube. The center thereof has an annular rib 221 . At least one notch 222 is formed on the edge of the annular rib 221 . The edge of the annular rib 221 having the notch 222 has a reduced step to be formed as a buckle edge 223 for being engaged with the water-stop washer 23 and the small washer 24 . Then a plug 25 is coupled to the water-stop washer 24 . One side of the cover 22 is extended with a pair of symmetrical extending arms 224 , 225 . A distal end of each extending arm 224 ( 225 ) is formed with a notch 2241 ( 2251 ). Two posts 321 at two sides of the lower section of the water tube 32 can be coupled to the notches 2241 , 2251 . Thereby, the posts 321 are utilized as fulcrums and the backside of the cover 22 has a hooking hole 226 for hooking a chain 21 . Another end of the chain 21 is hooked to the linkage 33 .
[0016] The water-stop washer 23 is a round soft piece with a round hole 231 at a center portion thereof. The water-stop washer 23 is mounted between the cover 22 and the plug 25 as a draining-preventing means.
[0017] The small washer 24 is a round hard piece with a round hole 241 at a center portion thereof.
[0018] The plug 25 is a hollow hemisphere. A top thereof is formed with a water inlet 251 , one lateral side has an air hole 252 . A lower portion of the plug 25 is extended with a flange 253 .
[0019] In assembly, the water-stop washer 23 , small washer 24 and plug 25 are sequentially assembled to the annular rib 221 of the cover 22 . By the notches 2241 and 2251 on the extending arms 224 , 225 of the cover 22 to hook the posts 231 at the lateral side of the water tube 32 , the cover 22 can cover the hooking hole 226 of the linkage 33 and the cover 22 (referring to FIG. 3). As a result, when one air hole 252 of the plug 25 is positioned at an upper side, as shown in FIG. 4, and the cover 22 is opened, since the water pressure of the water box will reduce with the reduction of the water level, the water in the water box will flow into the plug 25 from the water inlet 251 . Thus the plug 25 become heavier. Thus, the cover 22 will sink downwards to cover a draining hole 31 , but now the water in the water box does not drain out completely. Thus the water used is reduced. When the plug 25 is rotated so that the air hole 252 is positioned at a lower position (referring to FIG. 5), the water in the water box will drain out. Due to the water pressure effect of the water in the water box, it is difficult for the water to flow into the plug 25 . As a result, the cover 22 covers the plug 25 slowly. Thereby, the water in the water box is drained out completely by the positioning of the air hole 252 of the plug 25 . Therefore, the speed of the covering operation is controlled, and thus the water stored in the water box is adjustable.
[0020] The present invention is 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 present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A water-stop plug for adjusting water-draining of a stool comprises a cover, a water-stop washer, a small washer and a plug. The water supply of the water-stop plug for adjusting water-draining of a stool is adjustable according to the requirement of the user so as to save supplied water. By adjusting an air hole on a plug, the supplied water is adjustable.
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RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/888,209 filed on Oct. 8, 2013, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The invention generally relates to resins made from cashew nutshell liquid and vinyl hydrocarbons, and processes for manufacturing the resins.
BACKGROUND OF THE INVENTION
Phenol-modified hydrocarbon resins are widely used in coatings and adhesive formulations, and also widely used in the manufacturing of rubber products. These resins improve the compatibility of the ingredients in such formulations. In addition, the resins provide improved chemical and weathering resistance to finished products designed to perform under harsh environmental conditions, such as wide variation of temperature, oxidation by air, and light exposure. Other advantages include the substantial improvement of the adhesive properties in coating and adhesive formulations.
Phenol-modified hydrocarbon resins encompass a wide range of products produced by the reaction between phenols and vinyl aliphatic and aromatic monomers. In general, the composition of these resins is quite complex, which can be simply characterized by a mixture of monomeric and polymeric components bearing distinct chemical functionalities. For instance, the reaction of unsubstituted phenol with vinyl hydrocarbon monomers, such as styrene, alpha-methylstyrene, vinyltoluene, indene, coumarone, or any other similar vinyl monomers, or a mixture thereof, catalyzed by strong acids, produces liquid to wax-like resins containing variable amounts of short polymers of vinyl monomers, in addition to the alkylated phenol components. The polymer fraction is mostly composed of cyclic dimers and trimers of the vinyl monomers, with small amounts of respective linear oligomers. The alkylated phenol fraction is also multicomponent, as it contains variable amounts of monosubstituted, disubstituted, and trisubsituted phenolic compounds. The compositions of these resins can be controlled by careful adjustments of the reaction conditions. However, the most significant factor to control the desired physico-chemical properties is the judicial selection of structural variations on the phenol and on the vinyl hydrocarbon monomer building blocks. Mixtures of phenols and/or vinyl monomers are very often employed to achieve the right balance of polarity, solubility, and fluidity, which is intimately related to the hydroxyl functionality, the content of aromatic, hydrophobic moieties, and polymer fractions, in addition to the molecular weight distribution. For this purpose, it is a common practice to incorporate small portions of an alkyl-substituted phenol to the reaction mixture. The most commonly used alkyl-substituted phenols are ortho- and para-tert-butylphenol, octylphenol, and nonylphenol. These phenols can be produced in-situ, prior to or after the reaction with the intended vinyl monomers. These variations in the process can add cost and complexity to the manufacturing of such resins. In addition, it can be more difficult to stabilize the process and minimize the variability between batches as the number of steps and raw materials are increased.
Cashew nutshell liquid (CNSL) contains a large concentration of cardanol and cardols, a natural source of meta-substituted alkylated phenols and resorcinols. CNSL is relatively low cost, and it is a globally available bio-renewable commodity, which makes it an ideal building block for the manufacturing of phenol-modified hydrocarbons resins. Due to the structure of the components of CNSL, the hydrocarbon resins can be manufactured with fewer steps and/or raw materials.
Among the advantages of cardanol-based hydrocarbon resins are low viscosity, improved solubility with organic solvents, very low cloud points, and compatibility with a great number of resins and polymer formulations.
SUMMARY OF THE INVENTION
The present disclosure relates to resin compositions comprising cardanols obtained from Cashew Nut Shell Liquid (CNSL) and processes for making the resins. In one embodiment, the resins may be comprised of vinylated cardanols and vinylated cardols, wherein the cardanols and cardols are obtained from CNSL, as well as hydrocarbon cyclic dimers. The resin may include one or more additional polymers.
The resin may be manufactured by combining in a reactor vessel a quantity of CNSL, an acid catalyst, and a vinyl monomer, and maintaining the reactor vessel at a predetermined temperature for a predetermined period of time to achieve the desired degree of polymerization. As one skilled in the art will recognize, the proportions of the components to be used, the temperature and the time may be adjusted as desired to achieve a desired degree of polymerization of the components.
The resins may be used in coatings, as tackifiers, and for numerous other products that may use or include hydrocarbon resins.
DESCRIPTION OF THE FIGURES
For a better understanding of the present invention, reference is made to the following detailed description of an exemplary embodiment considered in conjunction with the accompanying drawings.
FIG. 1 shows an exemplary cardanol molecule.
FIG. 2 illustrates generally the reaction mechanism for one embodiment of the disclosure.
FIG. 3 shows the effect of different concentrations of a commercial phenol-hydrocarbon resin and CNSL hydrocarbon resin on the viscosity of a liquid epoxy.
FIG. 4 shows the results of a cross-hatch adhesion test on rusted S-36 panels treated with a pigmented white epoxy base formulation comprising CNSL hydrocarbon resin.
FIG. 5 shows a tested panel image of CNSL hydrocarbon system after 668 hours salt spray exposure.
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, the present disclosure is directed to resins produced by the reaction between Cashew Nut Shell Liquid (CNSL) and respective derivatives with vinyl hydrocarbons. The reaction may be promoted by acid catalysts. These resins are generally comprised of about 20-95% by weight of “vinylated” cardanols and cardols, about 1-40% by weight of hydrocarbon cyclic dimers, and about 0-50% by weight of polymers, which may be a mixture of short chains composed of vinyl hydrocarbon monomers and cardanol units, with degree of polymerization of no less than 2 and no more than 10 repeating monomer units.
In certain embodiments, the CNLS hydrocarbon resins comprise about 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% or 95% by weight of vinylated cardanols and vinylated cardols. Any of these values may be used to define a range for the percent by weight of the vinylated cardanols and vinylated cardols depending on the application. For example, the amount of vinylated cardanols and vinylated cardols in the CNSL hydrocarbon resin may range from about 25% to about 90% by weight, from about 30% to about 85% by weight, or from about 40% to about 80% by weight.
In certain embodiments, the CNLS hydrocarbon resins comprise about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, or 40% by weight of hydrocarbon cyclic dimers. Any of these values may be used to define a range for the percent by weight of the hydrocarbon cyclic dimers. For example, the amount of hydrocarbon cyclic dimers in the CNSL hydrocarbon resin may range from about 5% to about 35% by weight, from about 10% to about 30% by weight, or from about 15% to about 25% by weight.
In certain embodiments, the CNLS hydrocarbon resin comprises vinylated cardanols, vinylated cardols, and hydrocarbon cyclic dimers, and does not comprise any additional polymers. In other embodiments, the CNLS hydrocarbon resin comprises about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65% or 70% by weight of one or more additional polymers. Any of these values may be used to define a range for the percent by weight of additional polymers. For example, the percent by weight of one or more additional polymers in the CNLS hydrocarbon resin may range from about 1% to about 70%, from about 5% to about 45%, or from about 10% to about 40%. In certain embodiments, the one or more additional polymers are linear oligomers of vinyl hydrocarbon monomers and cardanols, with a degree of polymerization of 2, 3, 4, 5, 6, 7 8, 9, or 10 repeating monomer units. Any of these values may be used to define a range for the degree of polymerization of the additional polymers. For example the degree of polymerization of the additional polymers may range from 2 to 10, 3 to 9, or 4 to 8 repeating monomer units.
In another embodiment, non-purified CNSL is reacted with vinyl hydrocarbon monomers to make CNSL-based hydrocarbon resins. Non-purified CNSL is the raw product originated from the extraction process of the cashew shells. Depending upon the extraction procedure, the non-purified CNSL may contain relatively large amounts of cardols compared to purified CNSL. Also, depending upon the source, the total amount of cardols in non-purified CNSL can be as high as 25% by weight. Non-purified CNSL may contain large amounts of cardol and cardanol oligimers. The polymerization of cardols and cardanols can occur slowly under normal environmental conditions, although it can be accelerated by high temperature treatment, or it may be caused by oxidation processes during the CNSL extraction procedure. Also, depending upon the process of extraction, anacardic acid can be present in relatively high concentrations. The advantage of using non-purified CNSL is the lower cost of the raw material. The resins derived from non-purified CNSL can contain relatively high amounts of polymer, between about 5-35% by weight of the total resin. In certain embodiments, the resins derived from non-purified CNSL contain about 5%, 10%, 15%, 20%, 25%, 30% or 35% polymer by weight of the total resin. Any of these values may be used to define a range for the percentage of polymer in the resin. For example the percentage of polymer in the resin may range from about 10% to about 30%, about 15% to about 30%, or about 20% to about 25% of the total resin. The main advantages of hydrocarbon resins made with non-purified CNSL are related to their low migration, high hydrophobicity, and tackifier features. The most appropriate applications are additives for sealants, building materials, structural adhesives, and in manufacture of compounded rubber products.
In another embodiment, purified CNSL is reacted with vinyl hydrocarbon monomers to make CNSL-based hydrocarbon resins. Depending upon the purification procedure, the purified CNSL will contain reduced amounts of cardols, preferably below about 5%, and very low content of polymer species, preferably no more than about 2%. Also, anacardic acid is substantially completely removed from the CNSL. The major components of purified CNSL are the cardanol isomers, which are differentiated by the number of carbon double bonds on the side chain, as shown in FIG. 1 and described in U.S. Pat. No. 6,229,054, the contents of which are hereby incorporated by reference in their entirety. The total cardanol content is typically about 80 to 99% by weight, and is preferably about 85-99%, about 90-99% or about 95-99% by weight. The hydrocarbon resins made with purified CNSL are light colored, and exhibit low viscosity. The content of vinylated cardanols in the resins is typically about 20-99% by weight, and preferably about 50-95%, about 60-95%, about 70-95%, or about 80-95% by weight. Among the advantages of hydrocarbon resins made with purified CNSL are their light color, and anti-oxidant properties. These resins are particularly useful for coatings applications.
In yet another embodiment, highly purified CNSL is used. Depending upon the purification procedure, highly purified CNSL may contain only trace amounts of cardols, and essentially no polymer components and anacardic acids. They are essentially very pure cardanol mixtures, composed of only cardanol isomers which are differentiated by the number of carbon double bonds on the side chains. The total cardanol content is typically about 96% to 100% by weight, and preferably about 97% to 99.9%, about 98% to 99.9%, about 99% to 99.9%, or about 99.5% to 99.9% by weight. Depending upon the purification procedure the compositional distribution of the four cardanol isomers may vary greatly. In most cases, the content of cardanols with triene, diene, monoene, and saturated side chains are about 30-45% by weight, about 15-25% by weight, about 30-45% by weight, and about 0-10% by weight, respectively. In special cases, the content of isomers bearing multiple carbon double bonds on the side chains are intentionally depleted by means of physical separation or chemical reactions, to produce CNSL with better oxidation, color stability, and higher thermal transitions. For such purpose, the compositional distribution of cardanol triene, diene, monoene, and saturated isomers are preferably about 0-5% by weight, about 0-10% by weight, about 70-95% by weight and about 0-15% by weight, respectively.
In another embodiment, the distillation residue from the manufacturing process of the purified CNSL or the highly purified CNSL, characterized as a side stream, is also reacted with vinyl hydrocarbon monomers to make hydrocarbon resins. Depending upon the purification procedure, these side streams contain very high amounts of polymer components, high contents of cardols, and very low content of cardanols, and are substantially free of anacardic acids. The polymer content is characterized as a complex mixture of polymerized cardol and cardanols, normally caused by side chain polymerization, mostly through isomerization and cycloaddition reactions. The polymer can also originate from oxidative reactions. The molecular weight of the polymer fraction ranges from about 500 to 10,000 g/mol. The polymer level in this CNSL is about 20-95% by weight, and preferably about 30-80%, 40-70% or 40-60% by weight. The hydrocarbon resins produced using these side streams exhibit very high viscosity and enhanced hydrophobic properties. The resin may be used as a rheology modifier, an impact modifier, a tackifier, a plasticizer, a weathering stabilizer, and/or an anti-oxidant. They may also reduce cracking and brittleness of thermoplastic and thermoset polymer formulations, and the products made from these polymers. Due to the high polymer content of these resins, they may also be used in applications where control of leachates, migration, VOC, and other restrictive regulatory controls are required.
In another aspect, for the purpose of this disclosure, chemically modified CNSL streams are reacted with vinyl hydrocarbon monomers to make CNSL-modified hydrocarbon resins. Suitable chemical modifications can be carried out on the aromatic ring reactive sites, or on the double bonds of the side chains of the cardol, cardanols and anacardic acids components.
Any of the aforementioned purified or non-purified CNSL may react with aldehydes and ketones promoted by acid catalysts to form polymers of the novolac resin type. The same catalyst that converts CNSL substrates to CNSL hydrocarbon resins, can also promote the polycondensation reaction of cardol, cardanols or anacardic acids with aldehydes or ketones. Therefore, the CNSL-novolac-hydrocarbon resins can be made in one single batch process. The process can start with the production in-situ of the hydrocarbon resin, and then the polycondensation reaction is carried out with aldehyde or ketones in a subsequent step. Alternatively, under the same principle, the order of above steps can be reversed, in which case the CNSL-novolac resin is made first as an intermediate, followed by the reaction with the vinyl hydrocarbon monomers in a subsequent step. From the manufacturing perspective, the former manufacturing process is the simplest one, and therefore the preferred one.
Any of the aforementioned types of CNSL may be catalytically reduced with hydrogen under pressure and promoted by active metal catalysts to produce a partially or completely saturated product. This hydrogenated CNSL is allowed to react with vinyl hydrocarbon monomers promoted by acid catalysts to produce CNSL-based hydrocarbon resins featuring very low color, high chemical resistance and stability in weathering conditions. These hydrocarbon resins may be used in coating formulations, or in polymer product compositions that are intended to resist intense exposure to natural light. Alternatively, the hydrogenation process can also be done after the reaction between any type of CNSL stream and hydrocarbon vinyl monomers under similar conditions.
Any aforementioned CNSL-based hydrocarbon resins can be chemically modified afterwards, to attain special desirable features. As part of this disclosure, the carbon double bonds on the side chains of the cardanol in the aforementioned CNSL-based hydrocarbon resins can be epoxidized with hydrogen peroxide, or organic peroxides, or a combination of hydrogen peroxide and organic carboxylic acids. The degree of epoxidation can be selectively controlled by the reaction conditions, and by adjusting the substrate to peroxide feed ratios. These epoxidized CNSL-based hydrocarbon resins are suitable for lubricant compositions. The side double bonds can also be fully brominated with molecular bromine or other suitable organic and inorganic brominating agents, to produce resins with flame retardant characteristics.
Other common phenols can also be incorporated in hydrocarbon resins along with the CNSL to make resins comprised of variable amounts of CNSL building block in the final resin. These modifications may be useful for enhancement of specific desirable features. For instance, addition of bisphenol-A to the reaction mixture produces resins with high glass transition temperature. Lighter color, anti-oxidant properties, and light stability are other common enhanced features that can be achieved by the addition of about 2-70% by weight, and preferably 5-50%, 5-40%, 5-30% or 5-20% by weight of other simple synthetic phenols prior to or during the reaction of CNSL with the hydrocarbon vinyl monomers to make the respective blend of the desired CNSL and phenol based hydrocarbon resins. Examples of suitable phenols include, but are not limited to: phenol, nonylphenol, ortho-tert-butylphenol, para-tert-butylphenol, ortho-cresol, para-cresol, meta-cresol, technical grade mixture of cresols, bisphenol-A, bisphenol-F, hydroquinone, resorcinol, catechol, butylhydroxytoluene, methoxyphenol, tert-butylcatechol.
Suitable vinyl hydrocarbon monomers used in the manufacture of CNSL-based hydrocarbon resins are preferably the aromatic vinyl monomers, in which one or multiple alkene groups are linked directly to an aromatic hydrocarbon group, or to multiple aromatic groups that can be fused together or linked by single carbon-carbon bonds. Examples include, but are not limited to, styrene, alpha-methylstyrene, vinyltoluene (mixture of ortho, meta, and para isomers), indene, indene-coumarone streams from coal tar distillation, alpha-vinylnaphthalene, diisopropenylbenzene (and respective mixture of ortho- meta- and para-disubstituted isomers), the C9 fraction from a petroleum cracking process, divinylbenzene, and mixtures of divinylbenzene and ethylvinylbenzenes. Aliphatic and cycloaliphatic vinyl monomers can also be used alone or in a mixture with aromatic vinyl monomers. Examples of suitable aliphatic and cycloaliphatic hydrocarbon vinyl monomers include, but are not limited to, isobutylene, butadiene, isoprene, pentadiene, cyclopendadiene, dicyclopentadiene, pinenes (alpha and beta isomers), limonene, cyclohexane, vinylcylohexane, and mixtures of unsaturated olefins from the so called “C5 fraction” originated from oil refineries.
Suitable catalysts for the preparation of CNSL-based hydrocarbon resins may be strong inorganic protic acids, including, but not limited to, sulfuric acid, hydrofluoric acid, hexaflyorophosphoric acid, tetrafluoroboric acid, perchloric acid, or a mixture thereof. Lewis acids are also another good alternative to the inorganic protic acids, as they are very effective promoting Friedel-Crafts reactions, and similar alkylation reactions of phenols. Examples of suitable catalysts include, but are not limited to: boron trifluoride, boron trichoride, and respective complexes with phenol, alcohols, or tetrahydrofuran; zinc chloride, aluminum chloride, titanium (III) chloride, titanium (IV) chloride, zirconium (III) chloride, zirconium (IV) chloride, aluminum trichloride, aluminum phenoxide, reaction product of activated aluminum powder and CNSL. Boron trifluoride and respective complexes are the most preferred among the suitable Lewis acid catalysts because of their volatility, which simplify the procedure of catalyst removal from the finished product. A highly preferred catalyst class is the organic sulfonic acids, due to their moderate strength and activity to promote the reaction between CNSL-streams and vinyl hydrocarbon monomers. In addition, organic sulfonic acids are widely commercially available in high purity, they are relatively low cost, and pose less hazardous conditions on handling. More specifically, in respect to the manufacturing processes involving CNSL streams, organic sulfonic acids offer the best reaction control, with minimal side reactions, and better product composition uniformity. Examples of suitable organic sulfonic acids are, but not limited to, benzensulfonic acid; ortho-isomer, or para-isomers of toluenesulfonic acid, or mixture thereof; alpha-isomer, or beta-isomer of naphthalenesulfonic acid, and mixtures thereof; 1,5-isomer, or 2,6-isomer of naphthalenedisulfonic acid, and mixtures thereof; nonylphenolsulfonic acid, and mixture of respective isomers; dinonylnaphthylsulfonic acid, and mixture of respective isomers; dodecylbenzenesulfonic acid, methanesulfonic acid; trifluoromethanesulfonic acid, laurylsulfonic acid; phenolsulfonic acid and respective isomers; cresylsulfonic acid, and respective isomers. Preferably, all of the aforementioned sulfonic acids should have about 50-100% purity, and more preferably about 95.00-99.99% purity. The crystallized hydrate state of all of the aforementioned sulfonic acids are also suitable catalysts for the manufacture of CNSL-based hydrocarbon resins.
Solid state or supported acid catalysts are also suitable to promote the reaction between the aforementioned purified and non-purified CNSL and vinyl hydrocarbon monomers. These solid catalysts are insoluble in the reaction media, and generally they are in the form of microbeads, or coarse particulates, which are designed to have high surface area, improving the conversion rate. The major advantage of these catalysts relates to the simplification of the process for extraction of the acid catalyst from the final product by a simple filtration procedure. Conversely, soluble organic catalysts, in general, require neutralization, and subsequent wash and filtration steps, which can increase the time and cost of the manufacturing process. These catalysts are very well suited for semi-batch or continuous manufacturing processes for the production of CNLS-based hydrocarbon resins. Examples of suitable solid state or supported acid catalysts include, but are not limited to, nafion resins, sulfonated poly(styrene-co-divinylbenzene) resins, sulfuric aciddoped silica powder, acid activated montmorillonite, activated acid fullers earth, zeolite Y hydrogen form, zeolite ZSM-5 hydrogen form, zeolite beta hydrogen form, Zeolite mordenite hydrogen form, and acid activated bentonite clays.
The type and the amount of catalyst to be used in the manufacturing of CNSL-based hydrocarbon resins should be carefully selected based on the reactivity of the substrates, and the desired specification of the finished product. CNSL has the propensity to self-polymerize under the influence of strong acid catalysts at high temperatures. Therefore, under these conditions, the resulting CNSL hydrocarbon resin may exhibit high polymer fraction content as a consequence of these side reactions, which will result in high viscosity of finished products. Very low levels of acid catalyst are not satisfactory, because the conversion rate becomes very slow. In addition, the reactivity of the batch can be seriously compromised by the possibility of reaction inhibition (quenching) caused by small unpredictable and unwanted impurities. For strong inorganic and Lewis acid catalysts, which exhibit the higher catalytic activity, the optimal catalyst level is about 0.01 to 1.00% of the total weight of the reactants, and preferably about 0.05 to 0.2% of the total weight. In certain embodiments, the level of strong inorganic acid catalyst or Lewis acid catalyst is about 0.01%, 0.05%, 0.10%, 0.20%, 0.30%, 0.40%, 0.50%, 0.60%, 0.70%, 0.80%, 0.90% or 1.00% of the total weight of the reactants. Any of these values may be used to define a range for the percentage of the strong inorganic acid catalyst or Lewis acid catalyst. For example the percentage of the strong inorganic acid catalyst or Lewis acid catalyst may range from about 0.05% to about 0.5%, or from about 0.1% to about 0.5% of the total weight of the reactants. In the case of sulfonic acids, which exhibit moderate catalytic activity, the optimal catalyst level is about 0.05 to 5.0% of the total weight of the reactants, and preferably about 0.3 to 1.0% of the total weight.
FIG. 2 illustrates generally the reaction mechanism for one embodiment of the disclosure. As shown in FIG. 2 , cardanol may be combined in a reactor vessel with a hydrocarbon monomer in the presence of p-toluenesulfonic acid. The reactor vessel is maintained at a temperature of between 100-120° C. for a period of about 3 hours. The cardanol and hydrocarbon monomers react to form a CNSL hyrocarbon resin.
Prior to or after the production of CNSL-based hydrocarbon resins, certain additives can be added to attain certain desirable properties, or for better control of the manufacturing process, or to control the intended specifications of the final product.
The molar ratio between the CNSL and the vinyl hydrocarbon resin plays a significant role on the physico-chemical properties of the resulting resin. More importantly, it can deeply influence the performance of the resin for the intended application. Low [vinyl hydrocarbon monomer]/[CNSL] molar ratio ranges, such as about 0.8 to 1.8, produce resins with the lowest viscosity, with good compatibility with a variety of resins and polymer formulations, but reduced color and weathering stability. Medium [vinyl hydrocarbon monomer]/[CNSL] molar ratio ranges, such as about 1.8 to 3.0, produce resins with intermediate to high viscosity, but they exhibit enhance compatibility, color and weathering stability. High [vinyl hydrocarbon monomer]/[CNSL] molar ratio ranges, such as above about 3.0, produce resins with high to very high viscosity, and they may exhibit reduced compatibility or phase stability with other resins and polymer formulations, but they have excellent color and weathering stability, and enhanced anti-oxidant properties.
In certain embodiments, the molar ratio of the vinyl hydrocarbon monomer to the CNSL in the reaction mixture is about 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.5, 4.0, 4.5, 5.0, 6.0, 7.0, 8.0, 9.0 or 10.0. Any of these values may be used to define a range for the molar ratio of the vinyl hydrocarbon monomer to the CNSL wherein the properties of the different embodiments may have more than one property associated with more than one molar ratio range. For example, the molar ratio of the vinyl hydrocarbon monomer to the CNSL may range from about 0.8 to 10.0 or about 0.8 to 3.0.
The reaction between CNSL and vinyl hydrocarbons is carried out in sealed reactors in batch, semi-batch or continuous modes, protected from exposure to air, and preferably blanketed with an inert or reducing atmosphere. The temperature of reaction is a function of the reactivity of the CNSL, the vinyl hydrocarbon monomer, and the activity of the acid catalyst. For example, when the vinyl monomer is an aliphatic type and a Lewis acid catalyst is used, the temperature range for the process may range from about −10° C. to about 90° C., and is preferably between about 40° C. to about 60° C. When the vinyl monomer is an aromatic type and a Lewis acid catalyst is used, the temperature range for the process may range from about −10° C. to about 90° C., and is preferably between about 20° C. to about 60° C. When the vinyl monomer is an aromatic type and an inorganic acid or sulfonic acid catalyst is used, the temperature range for the process may range from about 50° C. to about 150° C., and is preferably between about 100° C. to about 120° C.
Even for the combination of substrates with the lowest reactivity, an exothermic reaction is observed at early stages of conversion. As the reactivity of the substrates increase, the temperature of the reaction must be adjusted to avoid side reactions due to temperature spikes, and the possibility of runaway reaction at early stages of conversion. The CNSL streams with relatively higher content of cardol exhibit higher reactivity. The less sterically hindered aromatic vinyl hydrocarbon monomers are the most reactive ones. Cycloaliphatic and aliphatic vinyl hydrocarbon monomers exhibit very low reactivity toward CNSL, and for such combination, high catalytic activity is required to achieve adequate conversions. For instance, for the reaction between any afore mentioned CNSL streams and styrene or vinyltoluene, the ideal temperature range for high active catalysts, such as boron trifluoride-phenol complex, the ideal reaction temperature is in the range of about −10° to 90° C., and preferably from about 40° to 60° C. For this same combination, but using para-toluenesulfonic acid monohydrate, the ideal reaction temperature is in the range of about 50° to 150° C., and preferably from about 100° to 120° C.
In certain embodiments the temperature for the reaction between CNSL and vinyl hydrocarbons is about −10° C., 0° C., 10° C., 20° C., 30° C., 40° C., 50° C., 60° C., 70° C., 80° C., 90° C., 100° C., 110° C., 120° C., 130° C., 140° C., or 150° C. Any of these values may be used to define a range for the temperature for the reaction between CNSL and vinyl hydrocarbons. For example, the temperature may range from about −10° C. to about 150° C., about 50° C. to about 150° C., or about 100° C. to about 150° C.
One embodiment of the process for carrying out the reaction between CNSL and the vinyl hydrocarbon monomer comprises dispersing the catalyst into the CNSL, followed by slow and controlled addition of the vinyl monomer into the CNSL/catalyst mixture.
A second embodiment of the process comprises adding at the same time the catalyst and the vinyl monomer through two different inlet ports (to avoid premature mixing of the catalyst with the vinyl monomer).
A third embodiment comprises dispersing the vinyl monomer into the CNSL, and then slowly adding the catalyst, or a suitable catalyst dispersion, with mixing. In this specific case, at early stages of conversion, the temperature should be significantly lower than the optimal level to avoid any potential temperature spikes or runaway reaction.
In each of the embodiments described above, the temperature is maintained in the ranges discussed above depending upon the type of vinyl monomer and the type of catalyst used.
In another embodiment, CNSL hydrocarbon epoxy resins, specifically glycidyl ethers of the aforementioned CNSL hydrocarbon resins, can be made from the reaction between epichlorohydrin and the desired CNSL hydrocarbon resin promoted by strong bases, such as sodium hydroxide or potassium hydroxide. CNSL hydrocarbon epoxy resins enhances the flexibility, and toughening characteristics of epoxy curing compositions, such as protective coatings, adhesives, and composites, without compromising the mechanical properties, compatibility, weather and chemical resistance. This feature makes them very advantageous over the traditional long aliphatic glycidyl ethers, which also promotes good flexibility, and toughening characteristics but at expense of reduced overall performance.
As noted in previous inventions [Process for manufacture of glycidyl ethers of polyhydric phenols, U.S. Pat. No. 2,801,227 A; and Preparation of liquid epoxy resins from bisphenols, U.S. Pat. No. 4,132,718 A], the use of a large stoichiometric excess of epichlorohydrin, and controlling the amount of water and the pH in the reaction medium also play a crucial role in minimizing side reactions that lead to significant amounts of undesirable inactive side products, high viscosity, low epoxy equivalent weight values, and high concentration of compounds with hydrolysable chlorine fragments.
Alternatively, CNSL hydrocarbon epoxy resins can be made from the epoxidation reaction of the allyl ethers of the desired CNSL hydrocarbon resin with inorganic or organic peroxides, or mixtures of hydrogen peroxide and carboxylic acids, such as acetic or formic acids. In turn, the referred allyl ethers of CNSL hydrocarbon resins can be made by the reaction between any aforementioned CNSL hydrocarbon resin and allyl chloride promoted by inorganic bases, such as sodium hydroxide or potassium hydroxide. Allyl bromide and allyl iodide are also suitable and more reactive alternatives to allyl chloride. The epoxidation of CNSL hydrocarbon resin allyl ethers may occur not only on the intended allyl group, but the unsaturations of the side chain can also be epoxidized all together. The allyl ether groups are more reactive, and hence more prone to epoxidation by organic and inorganic peroxides than the side chain double bonds of the CNSL building blocks. Therefore the degree of epoxidation can be controlled by the reaction conditions and the stoichiometric ratio of the reactants.
In another embodiment, alkoxylated CNSL hydrocarbon epoxy resins can be made from the reaction between any aforementioned CNSL hydrocarbon resin and an alkelene or cycloalkelene oxide promoted by acid or base catalysts under high temperature and pressure. The resulting alcohol or polyol are suitable for the 1-part or 2-part polyurethane systems used in semi-flexible and rigid foams, building materials, and adhesives. These polyurethane-polyols systems are very hydrophobic, and exhibit good mechanical behavior that is comparable to a great number of conventional aromatic polyether polyesters, in addition to improved impact resistance and flexibility. Examples of alkelene oxide include, but not limited to, ethylene oxide, propylene oxide, cyclohehane oxide, dicyclopentadiene diepoxide, and styrene oxide. The process for alkoxylation of CNSL hydrocarbon epoxy resins involves slow addition of alkelenes oxides to a mixture of CNSL hydrocarbon resin and catalyst at temperature in between 80 and 220° C., more preferably between 150 and 180° C., and under pressure of 10-150 psi, more preferably between 30-75 psi, and catalyzed by inorganic base, such as sodium hydroxide, or potassium hydroxide. The stoichiometric ratio between CNSL hydrocarbon resin and the alkelene oxide is judiciously chosen based on the desirable amount of alkelene oxide monomeric units appended to the hydroxyl groups of CNSL hydrocarbon resin. Large alkelene oxide to CNSL hydrocarbon resin equivalent ratios produce resins with long chains of polyalkene oxide appended to the CNSL hydrocarbon resins, which may render surfactant properties to the final product. Hence, surfactant is suitable for pigment dispersion aid, and rheology modifier in paint formulations.
Alternatively, ethoxylated or propoxylated CNSL hydrocarbon polyol resins can be made by reacting any aforementioned CNSL hydrocarbon resin with ethylene carbonate or propylene carbonate respectively, using the similar established manufacturing procedure for ethoxylated of plain cardanol [Cardanol derivative and method of making the cardanol derivative EP 1137620 A1]. This reaction is catalyzed by an organic or inorganic base. This procedure offers an advantage over traditional alkoxylation with organic oxides because it can be run at normal pressure, which simplifies the basic manufacturing equipment requirements. The most commonly catalysts employed for this specific mechanism of alkoxylation reactions are volatile organic amines, because they are very effective, and they can be easily removed from the reaction product by simple vacuum distillation. The reaction between CNSL hydrocarbon resin and ethylene or propylene carbonate is conducted at 100-220° C., more preferably between 150-180° C., and the amount of catalyst is generally between 0.1 to 10% of the total charge of reactants, but more preferably between 1-3%.
The following examples provide exemplary embodiments of the present invention, and the examples are not intended to limit the scope of the invention in any way.
EXAMPLES
Example 1
Pure CNSL—Alphamethylstyrene Resin
A 1 L round bottom multi-neck glass flask, equipped with a thermometer, a condenser, a mechanical stirrer, and an inlet port controlled by a peristaltic pump, was charged with 300 g or 1.0 mol of distilled CNSL (NX-4708M, Cardolite Co.). The whole set up was continually purged with a gentle flow of pure dry nitrogen. The temperature of the flask contents was raised to 80° C., and then 3.0 g of pure para-toluenesulfonic acid were added to the flask. Upon dispersion of the acid catalyst, 300 g or 2.54 mol of alpha-methylstyrene (Acros Chemicals Co, 98% pure) were added to the reaction mixture via the peristaltic pump, while the content of the flask was vigorously stirred. As soon as the addition started, the temperature was allowed to slowly rise up to 120° C. The addition rate of the styrene was adjusted to take about 15 minutes to completion. Then, the reaction mixture was allowed to react for an additional 120 minutes. The non-reacted alpha-methylstyrene was vacuum distilled using an oil pump, at 0.05 mmHg. The resin was dispensed as is without any further purification step.
The yield was 552 g of resin having the following properties: Brookfield Viscosity (300 rpm, 25° C., spindle #3)=358 cPs; Gardner color=10; free alpha-methylstyrene (by GC)=0.04%; free cardanol (by HPLC)=4.7%
Example 2
Hydrogenated CNSL—Vinyltoluene Resin
A 1 L round bottom multi-neck glass flask, equipped with a thermometer, a condenser, a mechanical stirrer, and an inlet port controlled by a peristaltic pump, was charged with 304 g or 1.0 mol of hydrogenated and distilled CNSL (NC-510, Cardolite Co.). The whole set up was continually purged with a gentle flow of pure dry nitrogen. The temperature of the flask contents was raised to 80° C., and then 3.0 g of pure para-toluenesulfonic acid were added to the flask. Upon dispersion of the acid catalyst, 312 g or 3.0 mol of vinyltoluene (Acros Chemicals Co, 98%, mixture of isomers) were added to the reaction mixture via the peristaltic pump, while the content of the flask was vigorously stirred. As soon as the addition started, the temperature was allowed to rise up to 120° C. The addition rate of the vinyltoluene was adjusted to take about 15 minutes to completion. Then, the reaction mixture was allowed to react for an additional 60 minutes. The non-reacted vinyltoluene was vacuum distilled using an oil pump, at 0.05 mmHg. The resin was dispensed as is without any further purification step.
The yield was 605 g of resin having the following characteristics: Brookfield Viscosity (300 rpm, 25° C., spindle #3)=2640 cPs; Gardner color=<1; free styrene (by GC)=0.04%; free hydrogenated cardanol (by HPLC)=0.25%
Example 3
Ultra-High Pure CNSL—Styrene Resin
A 500 mL round bottom multi-neck glass flask, equipped with a thermometer, a condenser, a mechanical stirrer, and an inlet port controlled by a peristaltic pump, was charged with 150 g or 0.5 mol of highly purified CNSL with cardol content lower than 0.1% (GX-2512, Cardolite Co.). The whole set up was continually purged with a gentle flow of pure dry nitrogen. The temperature of the flask contents was raised to 80° C., and then 1.5 g of pure para-toluenesulfonic acid were added to the flask. Upon dispersion of the acid catalyst, 104 g or 1.0 mol of Styrene (Acros Chemicals Co, 99.9% pure, stabilized with 0.1% TBC) were added to the reaction mixture via the peristaltic pump, while the content of the flask was vigorously stirred. As soon as the addition started, the temperature was allowed to rise up to 100° C. The addition rate of the styrene was adjusted to take about 45 minutes to completion. Then, the reaction mixture was allowed to react for an additional 90 minutes. The non-reacted styrene was vacuum distilled using an oil pump, at 0.05 mmHg. Then, a solution of 2.0 g of sodium bicarbonate (Acros Chemicals Co) in 50 mL of distilled water were added to neutralize the catalyst. The waste was vacuum distilled, and the resulting hazy oil was treated with filtration aid ceramic and filtered through a fritted funnel under vacuum.
The yield was 232 g of resin having the following properties: Brookfield Viscosity (300 rpm, 25° C., spindle #3)=455 cPs; Gardner color=3; free styrene (by GC)=0.07%; free cardanol (by HPLC)=1.9%
Example 4
Pure CNSL—Divinylbenzene Resin
A 1 L round bottom multi-neck glass flask, equipped with thermometer, a condenser, a mechanical stirrer, and an inlet port controlled by a peristaltic pump, was charged with 300 g or 1.0 mol of distilled CNSL (NX-4708, Cardolite Co.). The whole set up was continually purged with a gentle flow of pure dry nitrogen. The temperature of the flask contents was raised to 100° C., and then 2.5 g of pure para-toluenesulfonic acid were added to the flask. Upon dispersion of the acid catalyst, 195 g or 1.5 mol of Divinylbenzene (TCI America Co, mixture of meta-, and para-isomers, also containing 40% ethylvinylbenzene) were added to the reaction mixture via the peristaltic pump, while the content of the flask was vigorously stirred. As soon as the addition started, the temperature was allowed to rise up to 140° C. The addition rate of the divinylbenzene was adjusted to take about 30 minutes to completion. Then, the reaction mixture was allowed to react for an additional 30 minutes. The non-reacted vinyl monomers were vacuum distilled using an oil pump, at 0.05 mmHg. The resin was dispensed as is without any further purification step.
The yield was 485 g having the following characteristics: Brookfield Viscosity (100 rpm, 25° C., spindle #3)=6035 cPs; HPLC/GPC results: Mn=1,384 g/mol, Mw=2,241 g/mol, polymer dispersity=1.62; free cardanol=0.8%.
Example 5
Glycidyl Ethers of CNSL Hydrocarbon Resin
A 1000 mL round bottom multi-neck glass flask, equipped with a thermometer, a condenser, a mechanical stirrer, and an inlet port with a addition funnel with pressure equalizer feature, was charged with 336 g (1 equivalent-weight. based on hydroxyl group content) of styrenated ultra-high pure CNSL resin described in example 3, and 222 g (4 equivalent-weight) of epichlorohydrin, and the resulting mixture was stirred for stirred and warmed up to 65° C. in 30 minutes. Then, 52.8 g (1 equivalent weight) of a 50% by weight solution of sodium hydroxide in water were added via the addition funnel over 3 hours period. Meanwhile the water-epichlorohydrin azeotrope from the reaction mixture was distilled under vacuum at 150-170 mmHg out to a Dean-Stark trap, in which the condensed epichlorohydrin-water heterogenous mixture was decanted, and the epichlorohydrin layer was allowed to return to the reaction flask. Upon completion the addition of epichlorohydrin, the reaction mixture was stirred at 68-72 hours for one additional hour. Then, the excess of epichlorohydrin was removed from the reaction mixture by vacuum distillation at 70-90° C. and 100 mmHg. The resulting thick slurry was then extracted with a mixture of 100 g of xylenes and 100 g of water. The aqueous phase was decanted out, and the organic phase was filtered and evaporated under vacuum to remove xylenes. The resulting light color oil was then filtered through a short plug of Celite filtration aid.
The yield was 365 g having the following characteristics: Brookfield Viscosity (100 rpm, 25° C., spindle #3)=609 cPs; Gardner color=6; Epoxy equivalent weight=618, hydrolizable chlorine content=0.18%.
Example 6
Ethoxylated CNSL Hydrocarbon Resin
A 1000 mL round bottom multi-neck glass flask, equipped with a thermometer, a condenser, and a mechanical stirrer, was charged with 336 g (1 equivalent-weight. based on hydroxyl group content) of styrenated ultra-high pure CNSL resin described in example 3, and 4.9 g (0.08 equivalent-weight) of triethylamine as a catalyst, and the resulting mixture was stirred under nitrogen and heated up to 155° C. Then, 58.1 g (1.1 equivalent weight) of molten ethylene carbonate were added to the flask over 3 hours period. Once completed the addition, the batch was stirred for another hour at 155° C., followed by vacuum distillation at 80-85° C. and 100 mmHg to remove any unreacted ethylene carbonate and triethylamine.
The yield was 362 g having the following characteristics: Brookfield Viscosity (100 rpm, 25° C., spindle #3)=655 cPs; Gardner color=7; Hydroxyl value=109 mgKOH/g.
Example 7
Application
The ability of CNSL hydrocarbon resin (from Example 3) to reduce the viscosity of liquid epoxy at different concentrations was investigated (e.g., viscosity reduction property). Six systems were tested in which the percentage of CNSL hydrocarbon resin in Epon 828 was 5%, 10%, 15%, 20%, 25% or 30%. The viscosities of the six systems were measured by using a CAP 2000+VISCOMETER (BYK). Similar systems using a commercial phenol-hydrocarbon resin were tested for comparison.
As shown in Table 1 below and FIG. 3 , use of CNSL hydrocarbon resin as a diluent resulted in a greater reduction in viscosity of the liquid epoxy in comparison to the commercial phenol-hydrocarbon resin.
TABLE 1
Viscosities of Liquid Epoxy and Hydrocarbon Resin Blends
Viscosities of liquid epoxy and hydrocarbon
Percentage of
resin blends @25° C./cps
hydrocarbon
With commercial
With CNSL
resin in liquid
phenol-modified
hydrocarbon resin
epoxy
hydrocarbon resin
(from Example 3)
0%
14280
14280
5%
10650
9165
10%
10031
7512
15%
9638
6313
20%
9150
5575
25%
8588
4853
30%
8156
4313
Investigation of Persoz hardness development was performed on a clear coating system (no pigment, additive and solvent added). A liquid epoxy Epon 828 and curing agent Versamid 115×70 system was used at stoichiometric ratio. 30% CNSL hydrocarbon resin or phenol-hydrocarbon resin (based on the weight of liquid epoxy) was evaluated.
For the Persoz hardness measurement, the testing panels were prepared by a BYK 15 Mirs wet application bar over QD-36 cold rolled steel panels (Q-panel, 3″×6″×0.020″). Persoz hardness numbers were obtained by using a Pendulum hardness tester (BYK Gardner) based on ASTM D 4366.
As shown in Table 2 below, the Persoz hardness results indicated that the system with 30% CNSL hydrocarbon resin gave faster cure property in comparison to the one with commercial hydrocarbon resin.
TABLE 2
Persoz hardness development of different
systems at 25° C. cure condition
Persoz hardness/sec.
With commercial
With CNSL
Cure time @
phenol-modified
hydrocarbon resin
25° C./day
hydrocarbon resin
(from Example 3)
2
30
40
5
125
149
9
168
187
The adhesion tape test (ASTM D 3359-97) was performed on rusted S-36 panels (Q-panel, 3″×6″0.020″) (adhesion over rust metal substrate). To obtain a uniform rusted surface, the clean S-36 panels were immersed in a 60° C. water bath (Precision circulating water bath, Model 260) for 24 hours followed by a warm tap water rinsing to remove the loosened rust. The panels were roughly dried with a paper towel and stored at room temperature for seven days before use.
TABLE 3
Pigmented white epoxy base formulation
Composition
Gray epoxy base (grams)
Liquid epoxy
30
CNSL hydrocarbon resin
6
(from Example 3)
Dispersant
3
Extender
65
pigment
13
Solvent
7.5
Flow control
0.6
Total of white epoxy base
125.1
Curing agent
44.7
Pigmented systems were applied over the rusted panels via a 10 Mirs wet application bar. After a seven-day room temperature cure, the cross hatch adhesion test was performed. As shown in FIG. 4 , there was 100% adhesion with no failure. The addition of CNSL hydrocarbon resin to coating system gave good adhesion property to rust metal substrate.
Salt spray exposure (ASTM B117) was evaluated based on the same formulation shown in Table 3 (anti-corrosion property). As shown if FIG. 5 , after 668 hours salt spray exposure, the test panel with 20% CNSL hydrocarbon resin exhibited no rust underneath the coating film except for a few small blisters near the scribed lines.
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The present invention is directed to resins made from cashew nutshell liquid and vinyl hydrocarbons and processes for manufacturing the resins. These resins exhibit lower viscosity than the phenol-based homologs. They also exhibit good compatibility with a wide range of solvents, mineral and natural oils, epoxy curing agents, liquid epoxy resins, and polymers, which make them suitable additives as non-reactive diluents for solvent-free coating formulations; tackifiers for structural adhesive, pressure sensitive and hot-melt adhesives; stabilizers for lubricants, fuel and polymer formulations; plasticizers for thermoplastic polymers and processing aid for rubber compounding and stabilizers for respective rubber artifacts. These resins are also valuable precursors for the manufacture of epoxy resins and polyols for coating, adhesive and composite formulations exhibiting ameliorated performance in water repellency, anti-corrosion, and fast hardness development during cure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to beverage containers. More specifically, the present invention relates to a double-walled beverage container having inner and outer walls joined at an upper rim and having a thermal break formed between the walls.
2. Related Art
Beverage containers exist in various shapes and sizes. One common type of beverage container is an aluminum can having a partially-removable tab and a finger lever for opening the tab. Once opened, a beverage can be consumed or poured through the opened tab. Various types of beverages, such as sodas, beer, etc., are contained in cans of this type.
Unfortunately, common aluminum beverage cans do not adequately insulate the contents of the can from heat outside of the can, due to the fact that the can is formed with a single wall which is thermally conductive. As a result, heat from the environment can heat the contents, and even more so, as one holds a cold beverage can, heat is transferred from one's hand to the contents of the can, adding sufficient heat to raise the temperature of the contents of the can to an undesirable level. One solution to this problem in the past is an insulating sleeve that fits over the can. Such sleeves are often made from foam or other similar insulating material. However such sleeves only partially fit over beverage containers, have poor insulating properties and are cumbersome to use. Other solutions relate to double-walled containers, however, these solutions do not provide a thermal break which extends, uninterrupted, along the entire side and bottom of the container.
SUMMARY OF THE INVENTION
The present invention relates to a beverage container having a double-walled construction with a thermal break. The container includes an inner wall with an inner bottom wall for containing a beverage, an outer wall which extends about the inner wall, and an outer bottom wall which extends under the inner bottom wall. A thermal break extends, uninterrupted, between the inner wall and the outer wall and the inner bottom and outer bottom walls. The container includes a top having an upper rim which joins the periphery of the top, the inner wall, and the outer wall. The upper rim could be formed using a crimping process, wherein the peripheral edges of the top, the inner wall, and the outer wall are crimped together.
The outer wall and the thermal break are co-extensive in height with the inner wall, so as to completely surround the inner wall, and the thermal break extends, uninterrupted, between the inner and outer walls and between the inner and outer bottom walls. The thermal break inhibits heat from the environment from being transmitted into the contents of the can, and even more so, heat from a person's hand when holding the container, to keep a beverage within the container cool. The thermal break could comprise air and/or a material which occupies all or part of the space between inner and outer walls (e.g., in the form of vertical strips of material, or annular rings of material), or the thermal break could be entirely comprised of a thermally non-conductive material.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the invention will be apparent from the following Detailed Description of the Invention, taken in connection with the accompanying drawings, in which:
FIGS. 1A-1B are side and top views, respectively, showing the beverage container of the present invention;
FIG. 2 is a cross-sectional view of the beverage container of the present invention, taken along line 2 - 2 of FIG. 1B ;
FIGS. 3-5 are cross-sectional views of the beverage container of the present invention, showing various configurations of the thermal break;
FIGS. 6A-8 are close-up, cross-sectional views showing steps for fabricating the beverage container of the present invention; and
FIGS. 9-10 are partial perspective views showing various configurations of the spacers of the beverage container of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a beverage container, described in detail below in connection with FIGS. 1A-10 .
FIGS. 1A-1B are side and top views, respectively, of the beverage container 10 of the present invention. The container 10 includes an outer wall 12 having an outer bottom wall 12 b, and an inner wall 14 having an inner bottom wall 14 b positioned within the outer wall 12 and the outer bottom wall 12 b for containing a liquid (e.g., a beverage). A thermal break 16 extends uninterrupted between the inner surface of the outer wall 12 and the outer surface of the inner wall 14 , and between the inner surface of the outer bottom wall 12 b and the outer surface of the inner bottom wall 14 b . The inner surface of the outer wall 12 and the thermal break 16 are co-extensive in height with the outer surface of the inner wall 14 , so as to completely surround the outer surface of the inner wall 14 to provide a thermal break along the entire height of the container. The thermal break 16 inhibits thermal energy outside of the outer wall 12 and the outer bottom wall 12 b (e.g., heat in the ambient air, or heat from a person's hand when the container 10 is held) from being transmitted into a liquid contained within the inner wall 14 and the inner bottom wall 14 b , to assist in keeping a beverage cool. The thermal break 16 could comprise air and/or a material which occupies all or part of the space between inner and outer walls 12 , 14 and inner and outer bottom walls 12 b , 14 b (e.g., in the form of vertical strips of material, or annular rings of material, discussed below), or the thermal break could be entirely comprised of thermally non-conductive material.
As shown in FIGS. 1A-1B , the container 10 is in the shape of a conventional beverage container (e.g., the shape of a beverage can). Of course, this shape could be varied as desired. The container 10 includes a tapered upper region 18 , an upper rim 20 , a tapered lower region 22 , and a recessed bottom region 24 . A tab 26 and an associated finger lever 28 could be provided, as in conventional beverage cans. The finger lever 28 can be raised by a person's finger to apply force to the tab 26 to partially separate the tab 26 from a top 30 of the can and to force the tab 26 below the top 30 , so as to open the container 10 to provide access to a liquid contained within the inner wall 14 and the bottom inner wall 14 b . Advantageously, the thermal break 16 extends along the entire height of the container 10 , up to the upper rim 20 , and along the entire width of the bottom of the container 10 (i.e., extending continuously between the outer bottom wall 12 b and the inner bottom wall 14 b ) so as to maximize insulation of the outer wall 12 from the inner wall 14 . Indeed, physical contact between the outer wall 12 and the inner wall 14 only occurs only at the upper rim 20 , thereby minimizing conduction of thermal energy between the outer wall 12 and the inner wall 14 . It is noted that the outer wall 12 and the outer bottom wall 12 b, the inner wall 14 and the inner bottom wall 14 b , and the top 30 , as well as the tab 26 and the finger lever 28 , could be formed from any suitable, lightweight material, such as aluminum (as is used to form conventional beverage cans).
FIG. 2 is a cross-sectional view of the container 10 of the present invention, taken along the line 2 - 2 of FIG. 1B . The thermal break 16 could include annular strips of material 32 positioned between the outer wall 12 and the inner wall 14 . The strips 32 could be attached to the inner surface of the outer wall 12 and the outer surface of the inner wall 14 to provide a degree of structural rigidity for the container 10 and to resist compression of the outer wall 12 against the inner wall 14 (e.g., when force is applied by a person's hand while handling the container 10 ). Also, the strips 32 could be formed (e.g., by coating) on either the inner surface of the outer wall 12 or the outer surface of the inner wall 14 prior to assembly of the container 10 , or prior to the formation of the walls. The strips 32 also function as a thermal break. The strips 32 could be formed of any suitable, lightweight material, such as plastic or foam.
FIGS. 3-4 are cross-sectional views of the container 10 of the present invention, wherein the thermal break 16 includes a plurality of vertical strips 34 are positioned between the inner surface of the outer wall 12 and the outer surface of the inner wall 14 . Similar to the annular strips 32 shown in FIG. 2 , the vertical strips 34 could be attached between the inner surface of the outer wall 12 and the outer surface of the inner wall 14 to provide a degree of structural rigidity for the container 10 , and to resist compression of the outer wall 12 against the inner wall 14 . Additionally, similar to the annular strips 32 , the vertical strips 34 also function as a thermal break, and could be formed (e.g., by dipping, coating, spraying, etc.) on the inner surface of the outer wall 12 or the outer surface of the inner wall 14 prior to assembly of the container 10 , or prior to the formation of the walls. The strips 34 could be formed from any suitable, lightweight material, such as plastic or foam.
FIG. 5 is a cross-sectional view of the container 10 of the present invention, wherein a continuous, uninterrupted layer of thermally non-conductive material 36 forms the thermal break between the outer wall 12 and the inner wall 14 , and between the outer bottom wall 12 b and the inner bottom wall 14 b , of the container 10 . The layer 36 could be formed from any suitable, thermally non-conductive material, such as plastic, foam, etc., and provides added structural rigidity for the container 10 . The layer 36 could be formed on the outer surfaces of the inner wall 14 and the inner bottom wall 14 b , or on the inner surfaces of the outer wall 12 and the outer bottom wall 12 b , using an suitable process, such as dipping, coating, spraying, etc.
FIGS. 6A-8 are close-up, cross-sectional views showing fabrication of the container of the present invention. One way of fabricating the container is shown in FIGS. 6A-6B . First, the inner wall 14 , the outer wall 12 , and the top 30 are formed using conventional fabrication processes for forming components of aluminum cans. Then, as shown in FIG. 6A , the inner wall 14 is positioned within the outer wall 12 , and a flange 40 created on the inner wall 14 extends over the upper end 38 of the outer wall 12 and serves to support and locate the inner wall 14 with respect to the outer wall 12 and the inner bottom wall 14 b with respect to the outer bottom wall 12 b , so that a thermal break extending along the sides and bottom of the container is provided. Also, the top 30 is positioned on the flange 40 , such that a flange 42 of the top 30 is nested on top of the flange 40 of the inner wall 14 . Then, as shown in FIG. 6B , the flanges 40 , 42 and end 38 are crimped inwardly or seamed to form the upper rim 20 . It is noted that other methods of attaching the top 30 and the inner and outer walls 12 , 14 as may be known in the art are within the scope of the present invention. It is noted that if the strips of the present invention are used, or if the thermal break will be filled with material, the strips of material could be positioned between the outer surface of the inner wall 14 and inner surface of the outer wall 12 , or formed on either the outer surface of the inner wall 14 or the inner surface of the outer wall 12 (e.g., by coating, spraying, adhering, or otherwise applying) prior to formation of the inner and outer walls, or after formation of the walls prior to positioning the inner wall within the outer wall.
Another way of fabricating the beverage container of the present invention is shown in FIGS. 7A-7D . First, as shown in FIG. 7A , the layer 36 could be formed on the outer surface of the inner wall 14 (e.g., by coating, dipping, spraying, etc.). Optionally, a gap 37 could be provided to facilitate joining (e.g., crimping or seaming) of the inner wall 14 , the outer wall 12 , and the top 30 . Of course, the layer 36 could extend entirely along the inner wall 14 with no gap. Also, the layer 36 could be formed on the inner surface of the outer wall 12 , if desired. Once the layer 36 is formed, the inner wall 14 is inserted into position within the outer wall 12 , in the general direction indicated by arrow A, such that the inner wall 14 rests within the outer wall 12 , as shown in FIG. 7B . In such circumstances, the layer 36 serves to support and position the inner wall 14 with respect to the outer wall 12 . Then, as shown in FIG. 7C , the taper 18 is formed by bending both the inner wall 12 and the outer wall 14 , using conventional techniques utilized to form the taper of existing beverage containers. Finally, as shown in FIG. 7D , the top 7 D is positioned on the inner wall 14 and the outer wall 12 , and the flanges 40 , 42 and the end 38 are joined together (e.g., crimped, seamed, etc.) to form the complete container. As can be seen, the layer 36 extends up to the top 30 .
Yet another way of fabricating the beverage container of the present invention is shown in FIG. 8 . First, a taper 18 A is formed in the inner wall 14 , using conventional techniques. Then, the layer 36 is formed on the outer surface of the inner wall 14 (e.g., by dipping, coating, spraying, etc.), and the inner wall 14 is inserted into position within the outer wall 12 . As mentioned above, the layer 36 could also be formed on the inner surface of the outer wall 12 . Once the inner wall 14 is in position within the outer wall 12 , a taper could then be formed in the outer wall 12 to match the taper 18 a of the inner wall 14 , so that both walls 12 , 14 are tapered (as shown in FIG. 7C ). Then, as shown in FIG. 7D , the top 30 and walls 12 , 14 could be joined, to form the complete container.
It is noted that any desired number of strips, in any desired spatial arrangement, could form part of the thermal break 16 of the container 10 . For example, as shown in FIG. 9 , three vertical strips 34 could be included in the thermal break 16 between the inner surface of the outer wall 12 and the outer surface of the inner wall 14 . Also, as shown in FIG. 10 , three annular strips 32 could be included in the thermal break 16 between the inner surface of the outer wall 12 and the outer surface of the inner wall 14 .
Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof What is desired to be protected is set forth in the following claims.
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A beverage container having a double-walled construction is provided. The container includes an inner wall with an inner bottom wall for containing a beverage, an outer wall which extends about the inner wall, and an outer bottom wall which extends under the inner bottom wall. A thermal break extends uninterrupted between the outer surface of the inner wall and the inner surface of the outer wall and the inner bottom and outer bottom walls. The container includes a top having an upper rim which joins the periphery of the top, the inner wall, and the outer wall.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to rakes and more particularly pertains to roller rake apparatuses which may be utilized for grating and leveling sand or other ground surfaces.
2. Description of the Prior Art
The use of rakes is known in the prior art. More specifically, rakes heretofore devised and utilized for the purpose of grating or clearing a ground surface are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
For example, a V-shaped lawn raking apparatus is illustrated in U.S. Pat. No. 5,040,365 which includes a wheeled unit adapted to detachably receive a generally V-shaped framework member having downwardly angled arm segments each provided with rake teeth thereon for removing and collecting debris as the apparatus is pushed across a lawn.
A lawn rake is described in U.S. Pat. No. 4,848,073 which includes a tine receiving rake head molded of a plastic material as an integral unit structure and includes a handle receiving portion and at least one tine mounting portion. The handle receiving portion includes a generally centrally located elongated socket portion for receiving therein one end of a handle to facilitate an ease of assembly.
Another patent of interest is a wheel rake as disclosed in U.S. Pat. No. 3,484,803 which illustrates a pull-type, rotary wheel, side delivery rake having a mobile main frame including a horizontal beam extending obliquely relative to the direction of travel for controlling a vertical position of the rake wheels.
Other relevant patents include U.S. Pat. Nos. 4,516,393, and 4,446,685.
While these devices fulfill their respective, particular objectives requirements, the aforementioned patents do not describe a roller rake apparatus having a plurality of rows of spaced rake tines and a pair of weighted rollers disposed in an operational relationship between the rows of tines for both leveling and grating sand or other ground surfaces.
In this respect, the roller rake apparatus according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of grating and leveling sand or other ground surfaces such as those found on a golf course.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of rakes now present in the prior art, the present invention provides a new roller rake apparatus construction wherein the same can be utilized for both grating and leveling sand or other ground surfaces. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new roller rake apparatus which has many of the advantages of the rakes mentioned heretofore and many novel features that result in a roller rake apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art rakes, either alone or in any combination thereof.
To attain this, the present invention essentially comprises a rake having a plurality of rows of spaced rake tines and a pair of weighted rollers disposed in an operational relationship between the rows of tines. The apparatus includes a substantially rectangular frame having rows of rake tines extending across a front end, a rear end, and medial portion thereof. Weighted rollers are positioned between the rows and a handle is pivotally connected to the frame for operation thereof by a standing user. The apparatus is particularly suited for grating and leveling sand such as that found on a golf course.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new roller rake apparatus which has many of the advantages of the rakes mentioned heretofore and many novel features that result in a roller rake apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art rakes, either alone or in any combination thereof.
It is another object of the present invention to provide a new roller rake apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new roller rake apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new roller rake apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such roller rake apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new roller rake apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new roller rake apparatus having a plurality of rows of spaced rake tines and a pair of weighted rollers disposed in operational relationship between the rows of tines.
Yet another object of the present invention is to provide a new roller rake apparatus which may be utilized for both grating and leveling sand or other ground surfaces such as those found on a golf course.
Even still another object of the present invention is to provide a new roller rake apparatus in which a length of the rake tines may be infinitely adjusted.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof, Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a roller rake apparatus comprising the present invention.
FIG. 2 is a side elevation view of the present invention.
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a bottom plan view as viewed from line 4--4 of FIG. 1.
FIG. 5 is an enlarged perspective view of a portion of a second embodiment of the present invention.
FIG. 6 is a side elevation view of the second embodiment.
FIG. 7 is an enlarged perspective view of a portion of a third embodiment of the present invention.
FIG. 8 is an enlarged side elevation view of portion of the third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the drawings, and in particular to FIGS. 1-4 thereof, a new roller rake apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
The roller rake apparatus 10 comprises a substantially rectangular frame 12 from which a plurality of rake tines 14 orthogonally project. The tines 14 are arranged in parallel spaced rows and a pair of rollers 16, 18 are rotatably coupled to the frame 12 and positioned between the parallel spaced rows of tines 14. A handle assembly 20 is pivotally connected to the frame 12 and allows a user to manipulate the roller rake apparatus 10 from a standing position. In use, the roller rake apparatus 10 may be positioned upon a surface to be groomed such as sand, dirt, fine gravel, and the like, and reciprocated by the user, whereby the tines 14 substantially grate the surface and the rollers 16, 18 operate to level the surface.
More specifically, it will be noted that the roller rake apparatus 10 comprises a substantially rectangular frame 12 comprising a pair of side members 22, 24 which are orthogonally connected to respectively opposed ends of both a front member 26 and a rear member 28, as best illustrated in FIG. 4. A pair of center members 30, 32 are positioned in a parallel, aligned relationship to both the front member 26 and the rear member 28 and are fixedly secured to the pair of side members 22, 24, proximate a medial portion thereof. A plurality of tines 14 are positioned in a spaced relationship along the front member 26, the rear member 28, and the center members 30, 32 and project orthogonally away therefrom.
A pair of rollers 16, 18 are positioned between the front and rear members 26, 28 and the center members 30, 32, respectively, and are rotatably supported upon axles 34, 36 which pass through an axial center of the roller and engage the frame 12. The rollers 16, 18 are illustrated in FIG. 3 as having a solid cross section, but it is within the intent and purview of the present invention to include rollers which are hollow and also rollers which have surface variations, such as patterns and the like, present thereon.
Pivotally connected to the frame 12 is a handle assembly 20 which allows a user to manipulate the roller rake apparatus 10 from a standing position. The handle assembly 20 comprises a substantially tubular handle 38 having a grip 40 at a first end and a substantially U-shaped member 42 secured to a second end thereof. The U-shaped member 42 is pivotally coupled to the pair of side members 22, 24 in a manner which allows the handle assembly 20 to rotate with respect to the frame 12, thereby allowing the frame to reside flatly against a ground surface independent of a position of the handle assembly 20.
In use, the roller rake apparatus 10 may positioned upon any surface to be both grated and leveled and then reciprocated by a user in a well understood manner. The tines 14 are operable to grate the ground surface and segregate any debris present therein. The rollers 16, 18 help to flatten any ground irregularities such foot prints, divots, and the like from the ground surface being raked.
A second embodiment of the present invention as generally designated by the reference numeral 44, which comprises substantially all of the features of the foregoing embodiment 10 and which further comprises a floating roller support assembly 46 will now be described. As best shown in FIGS. 5-6, it can be shown that the floating roller support assembly 46 allows the rollers 16, 18 to independently move with respect to the frame 12 in a plane substantially parallel thereto.
A pair of floating roller support assemblies are utilized to support both ends of each roller 16, 18. Only one of such pair of floating roller support assemblies is shown in FIG. 5 and it will be described in detail with it being understood that both of the floating roller support assemblies are substantially similar in design and function. Continuing then, it can be seen that the floating roller support assembly 46 comprises a pivot block 48 which is fixedly secured to the center members 30, 32 and which pivotally supports a pair of roller support arms 50, 52 thereon. The roller support arms 50, 52 project away from the pivot block 48 and are angled downward to support the rollers 16, 18 within the frame 12 as shown by the phantom illustration of FIG. 6. A catch 54 is slidably coupled to the pivot block 48 and is operable to secure the roller support arms 50, 52 in a down position, as best shown in FIG. 5. The catch 54 may be moved so as to allow the roller support arms 50, 52 to freely pivot upon the pivot block, thereby allowing the rollers 16, 18 to move with respect to the frame 12. A clip 56 is fixedly secured to the roller support arm 52 and is operable to engage the other roller support arm 50 to retain the roller support arms in a coupled relationship as shown in FIG. 6.
Comprising all the features and structure of the previous embodiments 10, 44 is a third embodiment which is generally designated by the reference numeral 60 and may be viewed in FIGS. 7-8. It can be shown that the third embodiment 60 further comprises an adjustable tine assembly 62 which allows a depth of the tines to be adjusted in an efficient manner. The adjustable tine assembly 62 comprises a further frame assembly 64 which is formed in a substantially identical manner as that of the frame 12. The further frame assembly 64 has a plurality of apertures which allow the tines to pass therethrough so that the further frame assembly may slide along the tines relative to the frame 12. A plurality of adjustment screws 66 are threadably engaged to the frame 12 and rotatably secured to the further frame assembly 64, as best shown in FIG. 8. The adjustment screws 66 each include a knurled grip 68 at a first end and an enlarged portion 70 at a second end thereof. The enlarged portion 70 of each of the adjustment screws 66 is operable to be received within a cavity 72 of the further frame assembly 64. Each of the adjustment screws 66 may be rotated with respect to the frame 12 to either increase or decrease a distance between the frame and the further frame assembly 64 to allow either a lesser or a greater portion, respectively, of each of the tines 14 to project through the further frame assembly and engage the ground surface upon which the third embodiment 60 is being operated.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A rake having a plurality of rows of spaced rake tines and a pair of weighted rollers disposed in an operational relationship between the rows of tines. The apparatus includes a substantially rectangular frame having rows of rake tines extending across a front end, a rear end, and medial portion for grating a ground surface. Weighted rollers are positioned between the rows and a handle is pivotally connected to the frame to facilitate an operation of the rake by a standing user. The apparatus is particularly suited for grating and leveling sand such as that found on a golf course.
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[0001] This application is a continuation-in-part of U.S. Provisional application Ser. No. 12/582,059 filed on Oct. 20, 2009 which is a continuation-in-part of U.S. design application 29/317,618 filed on May 2, 2008 which has issued as U.S. Pat. No. D602,531 on Oct. 20, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 11/132,238 filed on May 19, 2005, now abandoned, which claims benefit of U.S. Provisional Application 60/572,100 filed on May 19, 2004. Pat. No. D602,531 and U.S. application Ser. Nos. 12/582,059, 11/132,238, and 60/572,100 are hereby incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] Outdoor camping, picnicking etc. are common leisure pastimes. Frequently associated with such occasions is outdoor cooking on a charcoal or gas grill a smoker or other outdoor cooking apparatus. Traditional grilled foods include hamburgers, steaks, sausages etc. For cooking on a patio or in a backyard, the food is readily available. However, outdoor cooking is also performed at remote locations having no access to household refrigerators and conveniences. At these locations, supplying food can be an important and limiting consideration.
[0003] At outdoor cooking locations, usually the only locally available food, if any, is typically soft drinks, candy bars and other snack foods. Accordingly, travelers away from home must bring their own food for cooking. This practice has several disadvantages. The amount of food is substantially limited by the size of the food container, usually a cooler or ice chest. Container capacity is further limited by the presence of various means of keeping the content frozen; ice, dry ice, cool packs etc. Moreover, the frozen food begins to thaw almost immediately and is preserved for only about a single day. When the content of a cooler approaches room temperature, the consumer will face an uncertain deadline after which food is no longer safe to consume. Being highly adverse to the risk of food poisoning, a consumer will often discard food of questionable freshness even though the consumer cannot be sure that the food had actually gone bad.
[0004] Vending machines are well known in the art. There are many designs that can be adapted to deliver butcher shop meat products to the consumer at a remote location. Such suitable machines are described in U.S. Pat. No. 6,779,684 to Suk-Ho Shin, Suwon-si issued on Aug. 24, 2008, U.S. Pat. No. 7,055,716 to Holdway et al. issued on Jun. 6, 2006, U.S. Pat. No. 7,182,219 to Chang issued Feb. 27, 2007, U.S. Pat. No. 7,401,710 to Black et al. issued on Jul. 22, 2008 and 7,086,560 to Shioya, Morihisa issued on Aug. 8, 2006 each is hereby incorporated by reference in its entirety. Similarly, there also many known solutions to communicate with remote devices such as a vending machine, such methods are described in U.S. Pat. No. 7,889,852 to Craig Whitehead issued on Feb. 15, 2011, U.S. Patent Application Publication 20040046637 to Eveline Wesby Van Swaay published on Mar. 11, 2004 and U.S. Pat. No. 7,870,029 to Bates et al. issued on Jan. 11, 2011 each is hereby incorporated by reference in its entirety.
OBJECTS OF THE INVENTION
[0005] It is a general object of the invention to relieve the traveler of concerns about packing and preserving food for use in outdoor cooking.
[0006] Another general object of the invention is to provide a food service at a remote site that requires little or no effort on behalf of a remote site manager.
[0007] A further object of the invention is to effectively provide butcher shop service at remote locations.
[0008] Another object of the invention is to provide the remote service continuously; round-the-clock, seven-days-a-week.
[0009] A further object is to provide automated or self service butcher shop service where food products are dispensed and paid for without direct input from a butcher shop proprietor.
[0010] A still further object of the invention is to provide for efficient management of a remote butcher shop where inventories are automatically recorded and the operational conditions of machinery are automatically measured and recorded.
[0011] Still another object of the invention is to provide for remote management requiring little or no specific effort from the local site manager.
[0012] Another object of the invention to efficiently control a plurality of remote butcher shop service locations.
BRIEF SUMMARY OF THE INVENTION
[0013] An embodiment of the present invention that is intended to accomplish at least some of the foregoing objects comprises a system for dispensing fresh and frozen food to consumers at remote locations. Remote locations include marinas, campgrounds, urban parks and other locations. The system also includes small environmentally friendly self-service automated retail shops that will provide round-the-clock service, seven days-a-week. The shop can be configured to accept both cash and cashless payment, provide computerized transaction records and 24/7 telemetry to monitor performance, facilitate and accelerate stock replenishment and maintenance by allowing remote access to the telemetry. In a preferred embodiment, delivery and maintenance personnel can access the information, with a handheld device, either directly from the machine or indirectly from off site locations such as an internet web page.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a front view of an automatic butcher shop showing a typical selection of butcher shop food available for campground consumers;
[0015] FIG. 2 is a front view of a clear door vending machine embodying the teachings of the subject invention;
[0016] FIGS. 3 through 10 relate to the product separation and selection tray system which is adjustable and removable from the clear door vending machine;
[0017] FIG. 3 is a front perspective view of the product separation and selection tray system of the present invention;
[0018] FIG. 4 is a rear perspective view of the product separation and selection tray system;
[0019] FIG. 5 is a side view of the product separation and selection tray system;
[0020] FIG. 5A is a front view of an alternate embodiment of a product separation and selection tray system having an adjustable top support assembly for controlling the separation of opposing side walls from a central wall;
[0021] FIG. 5B is a front perspective view illustrating the details of the top support assembly;
[0022] FIG. 5C is a rear perspective view showing the details of the top support assembly;
[0023] FIG. 5D is an enlarged detailed view of the top support assembly mounted on a central wall of a cell assembly and illustrating opposing slidable top straps for engagement with opposed sidewalls;
[0024] FIG. 5E illustrates the top support assembly with one half of the assembly removed;
[0025] FIG. 5F is a side view of the top support assembly illustrating the internal workings of the top support assembly as seen through one of its side walls;
[0026] FIG. 6 is a bottom view of the product separation and selection tray system;
[0027] FIG. 7 is an exploded front perspective view of the product separation and selection tray system;
[0028] FIG. 8 is a front view of the product separation and selection tray system;
[0029] FIG. 9 is a rear view of the product separation and selection tray system;
[0030] FIG. 10 is a top plan view of the product separation and selection tray system;
[0031] FIG. 11 is a plan view of an X-Y axis product acquisition and transport system aligned with one column of the product separation and selection tray system prior to engagement of a projecting tab portion of a lever for release of product to a cup of the product acquisition and transport system;
[0032] FIG. 11A illustrates the details of a pusher assembly used to advance a product to be dispensed along a tray with a negator spring drum shown in a position of rest;
[0033] FIG. 11B is a rear view of the pusher assembly with the negator spring drum rotatably mounted in a foot which is used as a stop for a lesser compressive spring pushing on product to be dispensed;
[0034] FIG. 11C illustrates extension of the foot and therefore biasing of the negator spring drum by extension of a portion of the wound tape forming the drum so as to provide a bias force for return of the foot to the at rest position shown in FIG. 11A ;
[0035] FIG. 12 is a plan view illustrating the engagement of the cup of the product acquisition and transport system by engagement with the projecting tab of the lever of the separation and selection tray system so as to pivot a rotator out of engagement with the product and pivot a gate into engagement with a successive product;
[0036] FIG. 13 illustrates the release of the projecting tab of the lever so as to pivot the gate into alignment with a central wall for advancement of the successive product and engagement with the rotator;
[0037] FIG. 14 is a front perspective view of FIG. 11 ;
[0038] FIG. 15 is a left front perspective view of FIG. 12 ;
[0039] FIG. 16 is a front view of the vending machine of the present invention with the front door pivoted away from the cabinet to access the interior of the cabinet;
[0040] FIG. 17 schematically illustrates the X-Y axis product acquisition and transport system of the present invention;
[0041] FIG. 18 is a front view of the cup of the product acquisition and transport system holding a product on one side of the front door of the vending machine with the details of the interior of the control panel and delivery port having been omitted for clarity;
[0042] FIG. 19 is a perspective view of the cup holding the product as shown in FIG. 18 to illustrate the horizontal rail on which the cup slides;
[0043] FIG. 20 is a perspective view from the opposite side of FIG. 19 ;
[0044] FIG. 21 schematically illustrates the mechanism for tilting of the cup by engagement of a projection on a side of the cup with a projection extending from a fixed wall of the product delivery system;
[0045] FIG. 22 illustrates the opening of a slidable outlet port door or window and subsequent tilting of the cup to slide the product into the outlet port basket which is tiltable towards the consumer for access to and withdrawal of the product;
[0046] FIG. 23 illustrates the elevator cup first opening the port latch and contacting the delivery door;
[0047] FIG. 24 illustrates the complete opening of the delivery door and the pivoting of the elevator cup to deliver product to the port box while the port latch has dropped down to engage a weld pin to prevent the delivery box from being opened during delivery of the product;
[0048] FIG. 25 shows additional details of the delivery mechanism;
[0049] FIG. 26 is a rear view of the delivery box;
[0050] FIG. 27 is an enlarged view of the area encircled in FIG. 26 ;
[0051] FIG. 28 shows a detailed view of an approaching elevator cup including product for delivery and initial engagement of the port latch of the delivery door;
[0052] FIG. 29 illustrates the initial opening of the port latch and the contact of the delivery door;
[0053] FIG. 30 illustrates a rear view of FIG. 24 where the elevator cup has completely opened the delivery door, delivered the product to the port box and allowed the port latch to drop down and engage a weld pin to prevent the delivery box from being opened.
[0054] FIG. 31 is a rear view of the port latch having moved from the position shown in FIG. 26 so as to engage the weld pin;
[0055] FIG. 32 is a rear view where the elevator cup has released the delivery door allowing the port latch to disengage the weld pin, allowing the weight of the product being vended to rotate the port box forward to present the product to the customer;
[0056] FIG. 33 is a side view of the delivery box pivoted forward to allow release of the product to the consumer;
[0057] FIG. 34 is an illustration of one example of a communications module in a remote embedded application;
[0058] FIG. 35 is a more detailed illustration of a communications link distributed over the Internet;
[0059] FIG. 36 illustrates schematically the use of (TCP Transmission Control Protocol) ports and sockets for the controlled transmission of data;
[0060] FIG. 37 is a simple flow chart to illustrate a method of establishing a file transfer session between a remote embedded application and an ISP Server, with dynamic Public Key assignment;
[0061] FIG. 38 is a simple flow diagram to illustrate the steps in an initial registration procedure; and
[0062] FIG. 39 is a simple flow diagram to illustrate the initial steps in establishing a connection between an ISP Server and a remote application by use of Calling Line Identification (CLI).
DETAILED DESCRIPTION OF THE INVENTION
[0063] Managers of remote facilities seek to satisfy their customers with a clean, well run facility. By using the disclosed invention, these managers can provide an added value for their customers—for example, immediate on-site access to butcher shop services. More specifically, managers can provide a substantial selection of fresh and frozen food butcher shop items for outdoor cooking.
[0064] Ordinarily, it would be impractical for a marina or campground manager to supply butcher shop items. Substantial time commitments and experience are required to safely and profitably operate a butcher shop. One must deal knowledgeably with meat wholesalers and meat inspectors. Furthermore, one must know how to properly butcher sides of beef, know a myriad of public health and safety regulations and storage requirements to maintain meat in a safe and attractive display.
[0065] Finally, and perhaps most importantly, one must have a feel for what types of food items are popular with consumers. Stocking the correct items is critical for success of the operation which is dependent upon generating a reasonably large sales volume.
[0066] Surprisingly, the inventor has designed a practical system by which a remote site manager without any special knowledge in this field, can offer butcher shop services. As a result, a local manager can offer butcher shop retail services merely by supplying a 12 Amp, 110-volt electrical outlet.
[0067] Furthermore, the local manager will profit as a result of this service, either by receiving rental payments for the space allocated for the service or by receiving commissions based on the sales transactions. The manager will also profit in indirect ways. For example, a campground manager will provide an enhanced camping experience which will attract more campers, encourage campers to say on the campgrounds longer and return more often.
[0068] Remote locations will be provided with an automated dispensing apparatus stocked with carefully selected butcher shop food items. Such dispensing apparatus are portable. As used herein “portable” means able to be moved by a single human being through the use of a simple mechanical advantage, such as a hand truck or a dolly. Based on experience, each of the following selections are functional in the disclosed system. In order to be functional, each of the following foods must have physical properties such that they can be preserved for a sufficient time at the remote location and, after outdoor cooking, will suffer no significant losses in flavor.
[0069] The U.S. and Canadian Governments provide guidance and requirements for the food industry, of particular relevance are the guidance and requirements provided for the butcher and seafood industries. This information can be found in 21 C.F.R §§100-105, 110, 111, 113, 123, 130, 131, 133, 160, and 161 all cited sections of 21 C.F.R are hereby incorporated by reference in their entireties. In Canada analogous rules and guideline are provided in the Livestock and Poultry Carcass Grading Regulations, and the Meat Inspection Act of 1990, as well as the Fish Inspection Act, the three of which are hereby incorporated by reference in their entireties.
[0070] The specific method of cooking is also taken into account. The following foods are selected for compatibility with the specific types of outdoor cooking apparatus traditionally utilized: grills, gas grills, charcoal grills, hickory cooking, mesquite cooking, use of smokers, etc. In addition to the physical properties, these foods must have another property in order for the system to function optimally. Each of these food items are believed to be popular with the consumer found at the remote locations so that a sufficiently high sales volume can be established.
[0071] Some examples of the foods to be stocked are: ribs; marinated ribs; meat kebabs (chicken, beef, lamb, pork, etc); blackened chicken; chicken breasts; boneless strip steaks; filet mignon steaks, teriyaki steaks, hamburger, hamburger patties; pork chops, stuffed pork chops, beef London broil, Delmonico steaks, sirloin steak, Italian sausage, chicken cutlets, fish, and pork loin. On the other hand, some food items, while popular, are not practical for all but a few specific embodiments of this system; live Main lobsters, for example.
[0072] Some further specific examples of food items to be provided are: “country style” ribs marinated in barbecue sauce; precooked barbecue ribs; lemon/pepper chicken cutlets, cranberry stuffed chicken breast, gourmet steak burgers 90% lean, poached salmon in sweet red pepper sauce, and pork loin with apple sauce or apple cider sauce. It is also specifically contemplated to offer “all natural” or “organic” versions of the above food items.
[0073] Rather then building a permanent structure to house a retail shop, a portable structure will be utilized in accordance with a preferred embodiment of the invention. The various butcher shop items will be stored in an enclosed climate controlled structure. Specifically, the structure will be capable of refrigerating the items or freezing the items. Standard temperatures for refrigeration and freezing of butcher shop items can be used. The temperatures and atmospheric conditions inside the structure will be such that the food is preserved for the longest possible time without significantly effecting food quality.
[0074] In one preferred embodiment, humidity levels will be maintained such that the food will not undergo freezer burn. Alternatively, “frost free” freezing conditions can be used so long as steps are taken so that food items are rendered resistant to freezer burn. For example, the food items can be stored in individual compartments within the overall structure so that they will be substantially resistant to freezer burn. In another preferred embodiment, the food can be wrapper or otherwise packaged so as to be resistant to freezer burn. Any method of hermetically sealing the food can be used, for example vacuum sealing individual food items. Alternatively, the food stocks can be rotated or otherwise monitored so that the food does not remain under “frost free” conditions long enough for significant freezer burn to develop.
[0075] Preferably, stocking of the retail outlets will be accomplished by outside contractors. These contractors will monitor inventories by methods set forth below. When the stocks are depleted, the contractors will travel to the remote locations and restock the local retail shops. In one embodiment, the stocks are delivered to each individual retail shop from a central food warehouse. In another embodiment, a plurality of regional warehouses is used. Each regional warehouse is placed in a location convenient to service the retail shops in that region. Convenient regional warehouse locations can be, but need not be, a location central to that region's retail shops. Alternatively, the regional warehouse can be located close to a transportation hub; an airport, a common carrier pickup center, etc.
[0076] Regional warehouses are also contemplated when special needs arise, for example a group of retail shops that are close together but far from the central warehouse can be efficiently served from a regional warehouse. Also, retail shops with a high sales volume can be serviced from appropriately designed regional warehouses with extra storage space and delivery trucks to meet the high demand.
[0077] Another special design is to offer kosher food items. Sources of the ingredients are chosen and the status of all of the production, maintenance, delivery and storage equipment is monitored and controlled so as to ensure kosher certification from the appropriate authority.
[0078] Another preferred embodiment includes devices that can monitor the inventory automatically and report this data automatically. The inventory data can be obtained by a visit to the local retail site. Any manual or automatic method of reading data can be used in the invention. The inventory data can be read directly from a display on the structure and recorded on a clipboard. Alternatively, data can be read automatically by a hand held device, or laptop computer, then up loaded to a suitable database. An example of a suitable database would be a file server that can be accessed via an internet connection.
[0079] Still another suitable mode of data collection is to equip the local retail shop with a device capable of transmitting the data to a remote location without the need for a visit to the remote location. For example, inventory data can be sent by an internet connection to a site on the internet. In effect, the remote shop will automatically report its current inventory to the internet site. Thus, the supplier can stock his truck appropriately by monitoring the internet site without first having to visit the remote shop.
[0080] Food items will be displayed and dispensed to consumers in a similar manner to standard vending machines. Typically, the food is displayed with the use of transparent doors so that the consumer can see the food prior to making a purchasing decision. The price for each food item is displayed next to the food item. After the consumer tenders the appropriate payment, the food item is made accessible to the consumer using any of the myriad devices developed for use with vending machines. One specific embodiment of a preferred device is described below. Suitable devices are also described in U.S. Pat. No. 6,779,684 to Suk-Ho Shin, Suwon-si issued on Aug. 24, 2008, U.S. Pat. No. 7,055,716 to Holdway et al. issued on Jun. 6, 2006, U.S. Pat. No. 7,182,219 to Chang issued Feb. 27, 2007, U.S. Pat. No. 7,401,710 to Black et al. issued on Jul. 22, 2008 and 7,086,560 to Shioya, Morihisa issued on Aug. 8, 2006.
[0081] In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For instance for simplicity the vending item described is a breakable bottle, however, it is understood that fragile butcher cuts, fish filets, or even live lobster in a glass container with sea water could be substituted for the bottle in the below description.
[0082] With reference to the drawings, in general, and to FIG. 2 in particular, an automated food service system for remote recreational facilities embodying the teachings of the subject invention is generally designated as 30 . With reference to its orientation in FIG. 2 , the clear door vending machine includes a cabinet 32 with a front door 34 having a clear panel portion 36 .
[0083] On the front face of the door 34 is located a control panel 38 having a digital keypad 40 . Information entered into the digital keypad is displayed in display panel 42 . In addition, the control panel 38 includes coin slot 44 and dollar bill receiver 46 , as well as a change return slot 48 .
[0084] Representative samples of product separation and selection tray systems 50 for dispensing product through a delivery port 52 are seen through the panel 36 . A random scattering of the product separation and selection tray systems 50 is shown in FIG. 2 , it being understood that each of the shelves 52 a , 52 b , 52 c , 52 d and shelf 52 e (not shown) can accommodate up to four systems 50 on each shelf in the present width configuration of the systems 50 . The sidewalls of each system 50 are movable laterally to accommodate smaller or larger sized product to be dispensed by the vending machine 30 of the present invention.
[0085] FIGS. 3 through 10 are various views of the product separation and selection tray system according to the present invention. As shown in FIG. 3 , for example, the system 50 includes a base 54 and two opposed L-shaped side walls 56 and 58 . The side walls 56 and 58 are slidably mounted on the base 54 so as to be able to be varied in lateral separation distance from each other and from central fixed dividing wall 60 to accommodate various sized products to be dispensed.
[0086] To control the separation distance between sidewalls 56 and 58 , an adjustable top support assembly 320 is mounted on top of central fixed dividing wall 60 . The top support assembly 320 not only controls the separation distance between the sidewalls 56 and 58 but reinforces the upper extremities of the sidewalls so that the sidewalls do not bow outwardly due to the force of products being pushed along the base 54 of a system 50 .
[0087] The adjustable top support assembly includes two top straps 322 which extend from the centrally located support assembly 320 . One end 324 of each top strap 322 is L-shaped for anchoring to the sidewalls 56 and 58 . The opposite end 326 of the straps 322 is slidably mounted through slots in both of the two sidewalls 328 and 330 of the support assembly.
[0088] Extending from each of the sidewalls 328 , 330 is an indicia plate 332 , 334 , respectively. The indicia on plates 332 , 334 may include a scale with hash marks which matches the markings on plates 336 , 338 located on the base 54 of the system 50 . The relative positioning of the sidewalls 56 , 58 with respect to the indicia at the base 54 and on the plates 332 , 334 should match to ensure that the separation of the sidewalls 56 , 58 is the same at the top and at the bottom of the sidewalls.
[0089] As shown in FIG. 5D , each of the top straps 322 , includes a pointer arrow 340 which provides an indication of the relative positioning of the movable straps 322 to the fixed plates 332 , 334 for viewing the relative positioning of the upper portions of the sidewalls 56 , 58 . This positioning is compared to the markings of an arrow 342 on a projection 344 of the sidewalls 56 , 58 .
[0090] To control the position of the straps 322 as they pass through slots in the sidewalls 328 , 330 of the support assembly, a spring bias system and finger controlled strap lockers are located between the sidewalls 328 , 330 . The strap lockers 346 extend out in front of the support assembly 320 so as to be grabable and squeezed together by the fingers of an operator so as to release the bias on the ends 326 of the top straps 322 as they pass through slots in the upper ends of the sidewalls 328 , 330 .
[0091] As shown in FIGS. 5E and 5F , the top strap 322 passes through the side plate 330 , the side plate 328 having been removed in this Figure to view the interior between the two side plates 328 , 330 .
[0092] The strap locker 346 is pivotally mounted on a strap locker pivot 348 . A spring 350 extends between an anchor 352 mounted on an extension of the strap locker 346 and the opposite end of the spring 350 is mounted on an anchor 354 secured to the side plate 330 . It is therefore seen that the plate terminating in the strap locker 346 is pivoted so as to engage the strap locker 322 as the strap locker 322 passes through slots in the sidewalls 328 , 330 .
[0093] By pushing the two strap lockers together 346 by manual manipulation, the bias force may be removed to allow free sliding of the top straps 322 through the slots in the sidewalls 328 , 330 . Upon release of the strap lockers spring 350 and an additional spring 356 extending between anchors 358 and 360 , the strap lockers are controllable to either lock or release the sliding of the top straps 322 through the slots of the sidewalls 328 , 330 .
[0094] Regulation of the movements of the upper ends of the sidewalls 56 , 58 is thereby accomplished so that the separation distance between the sidewalls 56 , 58 is the same at their top as compared to their bottom. This strengthens the overall assembly and controls any tendency for the upper ends of the sidewalls to move apart.
[0095] An indicia display holder 62 (made of component parts 62 a and 62 b , as shown in FIG. 6 ) is located on a leading edge of base 54 . Display holder is used to identify a product's name, a price of the product and/or to identify indicia to be entered into keypad 40 to select a particular product.
[0096] Projecting in front of the label holder 62 is an actuating lever 64 . Actuating lever 64 controls operation of a rotator 66 and a gate 68 for dispensing of product from a space 70 defined between side wall 56 and central wall 60 or a space 72 defined between central wall 60 and end wall 58 .
[0097] As shown in FIG. 10 product is moved toward the leading edge of the system 50 by the use of feet 74 having a projection 76 which is slidable in a track 78 of the central wall 60 for placement of the feet relative to the forward end of the base 54 . Alternatively, the track may be positioned in the base.
[0098] Projecting forwardly from the feet 74 is either a single helix spring 80 or double helix spring 82 terminating in a slider 84 . The force of the springs 80 or 82 is sufficient to advance product in the direction of rotator 66 for dispensing of product into a delivery cup as will be explained in more detail later.
[0099] As will be explained with reference to FIGS. 6 and 7 , the product separation and selection tray system of the present invention includes rotator 66 having flat side surfaces 66 a and 66 b intersecting at one end and terminating at an opposite end in curved surfaces 66 c . At the intersection of flat surfaces 66 a , 66 b , is located an extended pin 86 having head 88 engaged in recess 90 at a leading edge 92 of central wall 60 . The opposite end 90 of pin 86 is engaged in a bushing 92 mounted on the upper surface of base 54 .
[0100] The pin 86 fixed in the rotator 66 allows pivotal movement of the rotator during movement of the tab portion 94 of the lever 64 . A pin 96 extends through arcuate slot 102 in the base 54 and through a slot 98 in the lever 64 to engage at its bottom end in bushing 100 . Pin 96 then passes into arcuate slot 104 of retaining plate 106 . Retaining plate 106 is secured to the underside of the base 54 as shown in FIG. 5 . The upper end of pin 96 is secured within rotator 66 at a point midway between sides 66 a and 66 b along a radial line projecting from pin 86 in the direction of curved side 66 c . The lever 64 is pivoted around boss 110 by the anchoring of circular opening 108 of the lever 64 in the boss 110 projecting upwardly from the retaining plate 106 .
[0101] For example, the rotators 66 shown on shelves 52 a , 52 c , 52 d and 52 e in FIG. 2 , illustrate the normal, at rest positioning of the rotators 66 . However, when the tab 94 is contacted and moved to the right as shown in the system 50 on shelf 52 b , the rotator 66 is pivoted such that side 66 a is in line, parallel with central wall 60 . Then rotator 66 allows product 112 to be advanced past rotator 66 under the bias force of spring 80 .
[0102] Simultaneous with the shifting of the rotator 66 is the movement of the gate 68 in an opposite direction. Gate 68 is mounted at one end on an elongated pin 114 having pin head 116 mounted in a recess 118 in central wall 60 . The bottom end 120 of the pin 114 is mounted in a circular recess 122 defined in a partition 124 separating the rotator 66 from the gate 68 .
[0103] A pin 126 extends through a circular opening 128 in the lever 64 and then passes through arcuate slot 129 in base 54 and arcuate slot 130 in the retaining plate 106 . The opposite end of pin 126 is secured in a recess in a trailing edge 132 of gate 68 . A rear terminal flange 134 of the lever 64 is slidable in arcuate slot 136 in retaining plate 106 .
[0104] In operation, when the tab 94 of lever 64 is moved in one direction, the lever 64 pivots about pivot boss 110 and the retaining flange 134 at the opposite end of the lever 64 moves in the opposite direction to the tab 94 . This action causes side 66 a of rotator 66 to move to a position parallel to central wall 60 . Gate 68 will simultaneously move its rear edge 132 in a direction perpendicular to central wall 60 in channel 70 so as to prevent advancement of a second, successive product in channel 70 against the bias force of spring 80 .
[0105] When force on tab 94 of lever 64 is released, two springs 109 a , 109 b return the lever 64 to its central, at rest position. This bias force would then force gate 68 to its at rest position, parallel to and within the confines of central wall 60 . The rotator 66 would also pivot to its at rest position as shown in the system 50 on shelf 52 a , for example. The return of the gate 68 to its alignment with central wall 60 would allow advancement of the second, successive product under the force of spring 80 until engaging with the rotator 66 , ready for the next dispensing operation.
[0106] By the adjustment of the sidewalls 56 , 58 , different sized products may be preloaded at a remote location onto a product separation and selection tray system of the present invention. When refilling the vending machine, an existing empty tray system 50 may be removed and replaced by a preloaded tray system 50 . Determination of product to be dispensed may thereby be made at a remote location with removal of an existing tray system and insertion of a new tray system at the vending machine.
[0107] Alternatively, new product may be pushed in from the front. Also, it is possible to remove the tray “on site” and add new product from the rear of the tray.
[0108] It is understood as being within the scope of the present invention that an engaging mechanism 140 as shown on the underside of the base 54 in FIG. 7 , can be used to engage with complementary shaped openings in a rear portion of shelves 52 a through 52 e . Therefore, as long as the total width of each shelf is known, the modular feature of the tray system 50 may be used to design mounting of an appropriate number of tray systems 50 on each shelf.
[0109] In FIGS. 12 through 16 , the progression of release of product 112 into an elevator cup 150 of a product acquisition and transport system is illustrated. Initially, the X-Y axis product acquisition and transport system is driven, based upon keypad actuation of a desired choice of product to raise the elevator cup in the Y-direction with selection channel 95 surrounding tab 94 of lever 64 . As shown in FIG. 12 , when the tab 94 of lever 64 is engaged by a sidewall 152 of channel 95 , upon sideways movement of the cup 150 , the rotator 66 moves out of the way of the product 112 and the gate 68 engages the next successive bottle or other vending item 154 .
[0110] The forward movement of the bottle or other vending item 154 is actuated by the slider 84 , as biased by spring 80 , until the bottle 154 engages the gate 68 as shown in FIG. 12 .
[0111] Alternatively, foot 74 is biased by a flat wound negator spring as shown in FIGS. 11 , 11 A, 11 B and 11 C. This is the primary force on the bottles or other vending items. Negator spring 300 is shown in the Figures in a wound state, rotatably mounted in foot 74 by axial pin 302 . Foot 74 is slidably mounted in a guide track 304 which may be secured to a side of a wall extending in a central portion of each product tray. Tabs 306 may be used to anchor the tray 304 in the side of central wall of the tray.
[0112] The foot 74 includes a recessed portion 308 for anchoring one end of spring 80 as shown in FIG. 11 . The base of the foot 74 includes an opening 310 through which a portion of the wound tape forming negator spring 300 may extend as shown in FIG. 12C . Extended portion 312 of spring 300 is anchored by pin 314 in the guide track 304 .
[0113] When the foot 74 is moved to the right with reference to FIGS. 12A and 12C and as shown in FIG. 12 , the portion 312 extends from the foot 74 . The natural tendency of the negator spring 300 to rewind to the rest position shown in FIG. 12A biases the foot to move to the left with reference to FIGS. 12A and 12C and thereby force spring 80 to move slider 84 into contact with a product to be dispensed. Alternatively, spring 80 may be omitted and the foot 74 directly engaged with the product to be dispensed.
[0114] Spring 80 and slider 84 are used to move the last bottle or other final item past the gate and rotator. The release of the tab 94 by reverse lateral movement of the cup 150 to the position shown in FIG. 14 releases the gate from engaging the bottle 154 and allows forward movement of the bottle 154 until engaging the rotator 66 .
[0115] During forward movement of the bottle or other vending item 112 , a sensor confirms placement of product in the elevator cup 150 . As shown in FIG. 12 , vertically extending flange 151 extends across the path of product in the cup 150 . As shown in FIG. 13 , the flange 151 is pivoted about pin 153 when product is pushed into the cup 150 . Pivotable flange 155 stabilizes the bottle or other vending item in the cup. A switch 153 is not actuated by flange 151 thereby indicating presence of a bottle.
[0116] FIGS. 14 and 15 show details of the flange 157 for use in guiding movement of the cup 150 with respect to horizontal movement by connection to a tension element such as a horizontal toothed belt. Also guide wheels 159 a , 159 b , 159 c assist in traversing along a horizontal guide rail as the guide rail is raised vertically for positioning of the cup in front of a tray system 50 .
[0117] FIG. 17 schematically illustrates the product acquisition and transport system 160 for movement of the cup 150 to any position in front of a product to be dispensed as well as for movement of the cup to deliver the product to a discharge port. Cup 150 is secured to tension element 162 which may be a belt, chain or cable for movement of the cup by rotation of a fixed motor 164 . The motor is connected by a drive shaft 166 to a drive roller 168 . Actuation of the motor causes the tension element 162 to run across driven rollers 170 , 172 , 174 and 176 . The rollers 170 , 172 , 174 are mounted on a horizontal rail 178 . When the rail 178 is fixed in position, movement of the tension element 162 causes the cup 150 to traverse the rail so as to be located in front of a particular separation and selection tray system 50 .
[0118] Movement of the cup vertically is accomplished by a tension element 180 driven by a fixed motor 182 having drive shaft 184 and drive roller 186 . The tension element 180 is fixed to the rail 178 so upon actuation of the motor 182 , the tension element 180 rotates around driven roller 188 for vertical movement of the rail and thereby also the cup 150 .
[0119] In FIGS. 20 through 22 , various views are shown of the positioning of the cup adjacent to a delivery door (not shown). The product is shown in dotted lines, since for illustrative purposes, the elevated position of flange 151 indicates that product should not be present in the cup 150 .
[0120] For delivery of product from the cup, the discharge mechanism 150 as shown in FIGS. 22 and 23 is used. The product is delivered through a discharge window 192 by engagement of an upper wall portion 194 of the cup 150 with a projecting tab 196 fixed on a sidewall 198 of the discharge port. Continued downward movement of the cup causes three interconnected sidewalls 200 , 202 , 204 of the cup to pivot around pivot point 206 . The sidewalls 200 , 202 and 204 engaging a product, tilt the product until the bottom of the product clears the bottom wall 208 of the cup to allow the product to slide at an angle of approximately 45 degrees into open delivery window 192 . Smooth movement of the sidewalls 200 , 202 and 204 is ensured by a cam slot 210 of wall 202 passing along a fixed screw or a bolt, pin or rivet 212 .
[0121] As shown in further detail in FIG. 24 , release of product through the window 192 is allowed by the vertical movement of the cup 150 to engage a sliding delivery door 214 which normally covers the window 192 of a delivery box. The door 214 is moved by engagement of an edge of bottom 208 of the cup with a tab 216 of the door. The product is thereby released into a delivery box 218 which is allowed to tilt forward by gravity or by engagement with a finger of the consumer in a finger hole or finger recess 220 . The delivery box 218 is tilted so that the product 112 may be grabbed by its cap 222 and removed from the machine.
[0122] A mechanism prevents the delivery box 218 from tilting out of the machine until after the door 214 is moved to the retracted position shown in FIG. 23 and the product is dropped into the basket. Not until upward movement of the cup and release of the sliding door, so that the door may cover the delivery window 192 , will the basket be allowed to be pivoted towards the consumer for access to the product. The prevention of pivoting of the delivery box 218 until the sliding delivery door 214 is closed, prevents the customer's hand from being injured during delivery of the product into the basket.
[0123] FIGS. 24 through 34 illustrate the delivery of product from the elevator cup 150 through the delivery window 192 after opening of the delivery door 214 and passage of the product into the delivery box 218 .
[0124] As shown in FIG. 24 , the product 250 approaches the delivery door 214 by rollers 159 a , 159 b and 159 c resting upon edge 252 of horizontal rail 254 . Horizontal rail 254 is moved vertically as was explained with reference to FIG. 18 . Driven rollers 256 a , 256 b are engaged by a tension element such as a driven chain (not shown), for example, so as to move the elevator cup 150 along the horizontal rail 254 .
[0125] When the delivery cup 150 is in the position shown in FIG. 23 , a port latch 258 located adjacent to an uppermost edge 260 of the delivery door 214 is engaged by a horizontally extending flange 262 located underneath the elevator cup 150 . As the elevator cup 150 is lowered with the horizontal rail 254 , the upper wall portion 194 engages the projecting tab 196 as was explained with reference to FIG. 22 and as shown in FIG. 25 . Simultaneously, the delivery door 214 is lowered vertically to open window 192 so that the bottle or other vending item 250 may be tilted, and by gravity, fed through the delivery window 192 . The downward movement of the port latch 258 causes engagement with a weld pin to lock the delivery box in position and prevent the delivery box from being opened. This is a safety feature so that the customer's hand is not inside the delivery box as the product is being dispensed.
[0126] In FIG. 26 , the bias force on the delivery door 214 is caused by anchoring a spring at one end on projection 264 whereas the other end of the spring (not shown) is secured to a projection 266 located at the bottom of the delivery door 214 . The door 214 slides in guide track 268 to ensure smooth movement.
[0127] As shown in FIG. 27 from the opposite side of the delivery door 214 , turned 90 degrees from that shown in FIG. 26 , an optic sensor emitter board 270 projects light beam 272 through holes 274 , 276 so that the line of sight with optic sensor detector board 278 is clear. When a clear line of sight is present, a signal is produced indicating that the delivery box is in position to receive a product. Counterweights 280 , 282 maintain the position of the delivery box in a closed position until a product is ready to be delivered and the delivery box is pivoted about pivot point 284 .
[0128] As shown in greater detail in FIG. 28 , the area encircled in FIG. 27 illustrates the port latch 258 in a rest position prior to the dispensing of product through the delivery door 214 . In this position, the delivery box 218 is movable. Movement is allowed because the port latch 258 has not yet engaged weld pin 286 in groove 288 of the port latch.
[0129] In operation, when the elevator cup 160 approaches the delivery door 214 as shown in FIG. 29 , a sensor switch 290 indicates engagement with the exterior wall 292 of the vending machine. The downward movement of the elevator cup first opens the port latch and then contacts the delivery door as shown in FIG. 30 .
[0130] As shown in FIG. 31 , the elevator cup 150 has completely opened the delivery door. The product 250 is delivered to the delivery box 214 . The delivery box is maintained in position by engagement of the port latch with the weld pin 286 as shown in FIG. 32 . This prevents the delivery box from being opened.
[0131] As shown in FIG. 32 , the bottle or other vending item 250 is located within the delivery box 214 so that, as shown in FIG. 33 , after upward movement of the door 214 , the weld pin 286 is released from the port latch 258 and is allowed to travel along arcuate guide groove 290 for controlling the pivotal movement of the delivery box. The weight of the product being vended rotates the delivery box forward to present the product to the customer.
[0132] The foregoing description should be considered as illustrative only of the principles of the invention. Since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and, accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
[0133] In addition to displaying the food items, messages can also be displayed to encourage sales. In one embodiment, an electronic blackboard is provided which is capable of displaying one or more messages depending on the time of day, the season of the year or other conditions. For example, sales or “specials of the day” can be displayed.
[0134] Any reliable payment system can be used in connection with the above disclosed system. Either cash or cashless payments are specifically contemplated. The remote location can be equipped with a device that enables automatic cash purchases, such as a currency reader. Specific cashless payment devices contemplated include payments via: credit card, debit card, ATM card, various prepaid debit cards, etc. In the later cases, the remote location can include a card reader. The cash-less payment modes are particularly convenient in view of the price of the various goods being offered which will be in the price range typically paid by consumers with credit cards and other cash-less payment cards.
[0135] Upon occasion, an operator may issue discount coupons, for example during a promotional event. The payment system can be configured to recognize discount coupons. The payment system can be configured to accept the coupon in the same manner that cash is accepted. The system will then read the coupons and deduct the appropriate amount from the food price.
[0136] A coupon can have a permanent denomination chosen when the coupon is printed. Alternatively, a value can be assigned to a coupon at a later time. For example, a coupon can be imprinted with a unique machine readable code. The payment system operator then programs a cash credit to be associated with that unique code. When the coupon is presented to the payment system, the credit is deducted from the purchase price.
[0137] Cash can be collected from the structure using any standard procedure. Cash can be collected by the same contractor hired to perform other services, such as restocking. Alternatively, a special contractor can be hired to perform cash pickups, for example an armored car carrier. The later embodiment, while more costly, is preferable in instances where a large amount of money is to be collected or when making collections in high crime areas.
[0138] The results of these various payment transactions can be monitored and reported in a manner similar to that of the inventory reporting. Telemetry can be obtained either manually or automatically, and can be gathered by visiting to the remote site or by transmittal from the remote site to a database.
[0139] In addition to stocking and payment systems, the invention also includes a maintenance system. The various devices at the remote location can be monitored by personal inspection. However, a preferred embodiment comprises a system of automatic monitoring. The status and performance can be manually or automatically monitored and recorded, as described above for other systems.
[0140] Telemetry sent from the remote location can be monitored on a round-the-clock basis. As a consequence, a breakdown will be immediately detected and addressed with an appropriate response, even if the breakdown occurs after normal working hours. The breakdowns can be the result of numerous causes; including device malfunction, power failure, vandalism and other causes.
[0141] FIG. 34 illustrates a remote embedded application, in the form of a vending machine 1 , or plurality of vending machine, which are arranged to communicate with a central site, in the form of an Internet Service Provider (ISP) Server 2 , over the Internet. Below we consider a single vending machine; however, it is understood the methods can be easily applied to a plurality of machines. Using the description below the same protocol can be used to allow two machines to communicate to one another.
[0142] The vending machine 1 incorporates an intelligent controller 10 which controls the normal functions of the vending machine 1 and also maintains a local database 11 which maintains a record of various parameters at the vending machine 1 —e.g. current operating status, performance, stock levels, currency levels, etc. (Some applications may have more than one controller such as 10 to perform and/or control different functions but, for simplicity, reference is made here just to one controller 10 , it being well understood by those skilled in the art that this may represent a plurality of controllers.)
[0143] The vending machine 1 also incorporates a communications module 12 which includes a module controller 121 , a modem 122 and i/o ports 123 . Although in FIG. 34 the module controller 121 , modem 122 and i/o ports 123 are shown separately from the vending machine controller 10 , any or all could alternatively be integrated with it.
[0144] The ISP server 2 is in effect a computer network server which is arranged to communicate simultaneously with a plurality of remote computers 201 , 202 . . . 20 n . Remote computers 201 , 202 . . . 20 n could be any of the following: a hand held device, a laptop computer, a database, an internet site, etc. In a preferred embodiment the remote computer 20 n is represented by a human, an off-site manager, interfacing with the system by listening to a voice through a telephone or VoIP, replies from the human if necessary can be from a key pad, key board, or translated by voice recognition software. The ISP server 2 further comprises a database 21 , a controller 22 , i/o ports 223 , a modem 23 and a clock 24 . For simplicity, the modem 23 is shown as within the ISP Server 2 although, in an Internet configuration, the modem 23 may typically be located at a different site than the database 21 , as illustrated in FIG. 35 , which is described in more detail below.
[0145] A communications link 3 is provided between the vending machine 1 and the ISP server 2 . The communications link 3 may take any suitable form but, in this example, utilises the Internet, which is accessed by both the vending machine 1 and the ISP server 2 via their respective modems 122 and 23 . However, it is to be understood that the communications link 3 could take any convenient form, which does not necessarily require the use of a modem such as 122 or 23 at either end of the link Both hard wired and wireless links maybe employed, as may both dial-up and permanent connections (e.g. Ethernet, ADSL, Intranet, WAN, etc.).
[0146] The vending machine 1 , together with the ISP server 2 and the communications link 3 , make up a communications system which operates as follows.
[0147] When it is desired for the vending machine 1 to communicate with the central database 21 , either upon a reportable condition arising at the vending machine 1 or at predetermined periodic intervals, the module controller 121 initiates an Internet dial-up session via the modem 122 , and establishes a link with the ISP server 2 (of known IP address). This may be, for example, by way of a Telnet session, with the module controller 121 providing an ID (username/password) to log onto the database 21 .
[0148] Once the Telnet session has been established, the ISP server 2 synchronizes a local clock 14 of the vending machine 1 with the dock 24 of the ISP server 2 . Updating the local vending machine dock 14 in this way enables any necessary time adjustment at the vending machine 1 , to provide more accurate synchronization as to time and date, as between the vending machine 1 and the ISP server database 21 . Alternatively, the clock 14 of the vending machine 1 may need to be synchronized with the clock 24 of the ISP server 2 , only when the module 12 is first installed and powered up (see below).
[0149] The communications link 3 having thus been set up, the ISP server 2 establishes an (File Transfer Protocol) session back to the vending machine module 12 , which is set up to operate as an FTP Server. To this end, the ISP server 2 looks up from the database 21 an appropriate ID (username/password) for the particular vending machine module 12 , to establish the FTP session.
[0150] At that point, the ISP server 2 takes control of any necessary exchange of files with the vending machine module 12 . It is important to appreciate that, in order to establish such an FTP session, it has not been necessary for the ISP server 2 to initiate a call to the remote embedded application of the vending machine 1 . On the contrary, it is the vending machine 1 that has initiated the call. But once the initial (e.g.) Telnet session has been set up, the ISP server 2 then takes over and sets up the FTP session.
[0151] Also, since control of the exchange of files in the FTP session between the database 21 and the vending machine module 12 rests entirely with the ISP server 2 , substantially all intelligence and control may remain at the ISP server 2 , with the vending machine module 12 having only minimal requirements. This arrangement provides substantial flexibility, since “decision making” software need not be embedded in the remote module 12 . This allows for much simpler software upgrades to the system. In most case, software upgrades can be accomplished entirely by a single operation at the ISP server 2 , rather than at many remote modules such as 12 . The absence or minimization of decision-making software at the remote unit 12 minimizes code downloads when new decisions need to be made. The remote unit 12 can request the database server 2 for certain actions—for example, download a specific file. However, the database server 2 can override any requests due to other events—for example, if a PC user (see below) has requested a specific function which takes priority.
[0152] With the FTP session established and any necessary time adjustment made as between the ISP server clock 24 and the vending machine dock 14 , files can be exchanged between the ISP server database 21 and the vending machine database 11 as necessary. For example, latest vending machine prices may be downloaded from the ISP server database 21 to the vending machine database 11 , when the time and date stamping of files indicates that the files at the vending machine 1 require updating. The ISP server database 21 , under the control of controller 22 , will automatically upload the latest collected data files from the vending machine 1 for example, vending machine stock levels, currency levels, etc. File transfers may take place in response to requests from the module 12 (or a remote computer 201 , 202 . . . 20 n )—for example, in response to a flag set at the module 12 (or remote computer) to indicate a file transfer request.
[0153] Once the files between ISP server database 21 and vending machine database 11 have been synchronized, the ISP server 2 can then teardown the FTP session.
[0154] Thus, in this way, significant advantages of ease and cost of communication can be obtained, firstly by making use of the Internet (where local call charges usually apply) to provide communication between the remote embedded application and the ISP server 2 , and secondly by employing a relatively simple communications controller 12 in the remote embedded application, to leave intelligence and control of file transfer sessions principally with the ISP server 2 . As noted above, there is no requirement for the ISP server 2 to initiate a call to the remote embedded application. The remote embedded application initiates the call, but the file transfer is then set up by the ISP server 2 . The transmission of real-time information from the ISP server 2 to the remote embedded application over the initial Telnet session can be particularly advantageous to ensure correct time sequencing of the files at the respective ends of the communications link.
[0155] As mentioned above, in an Internet implementation, the modem access may typically be more distributed than shown in FIG. 34 . This is shown in more detail in FIG. 35 . Here, the remote module 12 connects with an ISP modem server 23 a , which provides a local point of presence, and communicates over the Internet 30 with database server 2 a , which contains database 21 , controller 22 and clock 24 . (The clock could be local to the database 21 as shown or derived from another clock source on the Internet network—e.g. an atomic clock source.) Likewise, remote computer 201 ( 202 . . . 20 n ) connects with another ISP modem server 23 b , which provides another local point of presence, and communicates over the Internet 30 with database server 2 a.
[0156] In one example of an alternative configuration, the modems and Remote Access Servers of FIG. 35 can be dispensed with and the various components permanently connected, e.g. by way of an Ethernet or Intranet configuration. Either or both of the remote module 12 and remote computer could have respective databases which are either local or remotely connected over the network.
[0157] The structure of the ISP server 2 is such as to facilitate the lookup of Public Encryption Keys, which will be different for the Telnet and FTP sessions. The Telnet Public Key will be a key which is common to the ISP server 2 , which typically will service a large number of embedded applications, such as the vending machine 1 . However, the FTP Public Key can be unique to the vending machine module 12 . The latter feature enables a particularly advantageous encryption method, which combines simplicity with high security. This operates as follows.
[0158] Once files between the ISP server database 21 and the vending machine database 11 have been synchronized, and before the current FTP session ends, the ISP server 2 can send to the vending machine module 12 a new Public Encryption Key for the next FTP session on the next call from the vending machine module 12 . In other words, each time a new FTP session is initiated by the ISP server 2 , it uses a Public Encryption Key for the vending machine module 12 (operating then as an FTP Server) which has been transferred as a file to the vending machine module 12 during the previous FTP session. It will be appreciated that this affords a high degree of security. By the same token, it also allows a more simple encryption algorithm to be used for a given degree of security, since data synchronisation FTP sessions between the ISP server 2 and the vending machine module 12 will typically be small and therefore more difficult to crack, when the FTP Public Key is changed dynamically from one session to the next.
[0159] FIG. 37 is a simple flow chart to illustrate the above-described method of establishing a file transfer session between remote embedded application 1 and ISP Server 2 , with dynamic Public Key assignment.
[0160] In step 41 , an event occurs to trigger a connection request between vending machine 1 and ISP Server 2 . For example, this may be due to a particular event arising at the vending machine 1 , or to a particular time event arising, which requires a routine connection to the ISP Server 2 .
[0161] In step 42 , the communications module 12 dials up the respective Internet Service Provider and, in step 43 , logs on to the ISP Server 2 with appropriate ID, by way of a Telnet session.
[0162] In step 44 , the ISP Server 2 looks up the ID received in the initial Telnet session, in order to identify the particular communications module 12 . In step 44 , the ISP Server 2 logs on to the communications module 12 to establish an FTP session, using the FTP Public Key as sent to the module 12 during the last file transfer session.
[0163] In step 46 , file transfer proceeds between the ISP database 21 and the remote application database 11 , under control of the ISP Server 2 and, during that file transfer process or at the end of it, the ISP Server 2 sends, in step 47 , a new Public Encryption Key to the module 12 for the next FTP session.
[0164] With all of the file transfers completed, the ISP Server 2 terminates the FTP session in step 48 .
[0165] Another preferred and advantageous feature of the illustrated communications system concerns the procedure for first installing the vending machine module 12 .
[0166] When installed, the vending machine module 12 is programmed with a unique serial number. It is also programmed to dial up and connect to a specific registration database when first installed and powered up in the vending machine 1 . In other words, as a new item of equipment, the vending machine module 12 requires only minimal programming. Many similar modules 12 can be programmed in almost exactly the same way with almost exactly the same information, each differing only in its own unique serial number.
[0167] When the vending machine module 12 dials up the registration database for the first time, the registration database identifies the specific module 12 by means of its unique serial number, and then programs the module 12 with all of its relevant customized configuration—such as, for example, Telnet and FTP passwords, FTP Public Encryption Keys, telephone numbers for local ISP access local telephone rates), customer name, customized web pages, new user configuration, subsequent database IP addresses, etc. Having been programmed with all of this data, the vending machine 12 is then ready to dial up the ISP server 2 over the communications link 3 , as described above, for regular Telnet/FTP sessions. Thus, the installation process for the vending machine module 12 is substantially automated. As indicated above, the initial registration procedure can include an initial dock synchronization step between a central clock such as 24 and the clock 14 of the module 12 .
[0168] The registration procedure for the remote module 12 is carried out in just the same way as the above-described ISP server access—that is an initial Telnet session followed by an FTP session. This is a real benefit of centralized decision-making as described above. The remote module 12 purely has files transferred through it. It does not need to know whether these are configuration files, as in the case of initial registration, or whether they are data files for normal operation. The registration database could be totally separate from the usual “application” database 21 , or it could actually be the same database.
[0169] FIG. 38 is a simple flow diagram to illustrate the steps in the above-described registration procedure.
[0170] In step 51 , the communications module 12 is installed in the remote embedded application 1 and, in step 52 , it is powered up for the first time. In step 53 , the communications module 12 dials up the registration database and in step 54 logs on to it with its predetermined ID which, as described above, may be its unique serial number, in order to establish a Telnet session.
[0171] In step 55 , the registration database looks up the ID supplied from the module 12 in order to identify the particular module and then, in step 56 , it synchronizes its own local clock (or the clock that it uses) with that of the module 12 .
[0172] In step 57 , the registration database logs on to the communications module 12 to establish an FTP session and, in step 58 , it transfers the necessary set up and configuration files to the module 12 . When all of this is completed, the registration database terminates the FTP session in step 59 .
[0173] As noted above, in addition to providing Internet service to a plurality of communication modules such as 12 for various remote embedded applications, the ISP server 2 also provides Internet service for a large number of remote computers 201 , 202 . . . 20 n which, so far as the ISP server 2 is concerned, will typically be connected as PC Browsers. Thus, a user on remote computer 201 , subject to submission of appropriate ID (username/password), can gain access to the database 21 and therefore obtain information as to the current state of the vending machine 1 at the last time a dial up session was established between the vending machine 1 and the ISP server 2 . This might be regarded as a “snapshot” in time of the status of the vending machine 1 . In this way, subject to suitable security restrictions, an owner of a number of vending machines (or other embedded applications) can view their status conveniently via the database 21 , over a relatively cheap and simple Internet connection via the ISP server 2 .
[0174] In an optional variant, the user of remote computer 201 can look directly at the vending machine 1 . This operates as follows.
[0175] Once connected to the ISP server 2 , the user of computer 201 can cause the ISP server to dial up the vending machine module 12 , which is provided with Calling Line Identification (CLI) Service, to indicate to the called module 12 the identity of the calling party. The ISP server 2 will cause the vending machine modem 122 to be called for one or more ring periods (or for a predetermined time, particularly if the CLI comes before the first ring, such that no-ring calls can be supported). The communications module 12 detects from the CLI that the ISP server 2 has called, and is programmed not to answer the call. However, the communications module 12 is programmed to dial back after a short duration to establish a Telnet session (generally as described above) with the ISP server 2 , which then in turn establishes an FTP session with the communications module 12 , also generally as described above.
[0176] Then, furnished with the appropriate IP addresses, the ISP server 2 connects the remote computer 201 directly with the vending machine 1 , via the communications module 12 . This enables the user of remote computer 201 to view the data in the remote embedded application in real-time, and optionally, exchange data files with it and/or the ISP server 2 .
[0177] In this way, the user of remote computer 201 ( 202 . . . 20 n ) can dial up and view any desired remote embedded application at will, using a communications link established over the Internet. Again, by use of the CLI, one is able to overcome the presently accepted restriction that ISP's will not initiate a call, and thereby ensure that any call charges remain with the owner of the vending machine module 12 , rather than being attributed to the ISP server 2 .
[0178] In the above procedure, the dynamically assigned IP address of the remote module 12 is captured at the database 21 and forwarded to the remote computer 201 . This allows the remote computer 201 to browse the module 12 directly, since the module has its own embedded web server. Therefore, this provides a mechanism for the remote computer 201 to interrogate the remote module 12 in real time. So far as the remote module 12 is concerned, it has had a request to synchronize with the database 21 , using Telnet/FTP sessions. The database controller 22 can make the appropriate decisions as to whether to transfer files and/or “connect” the remote computer 201 to the remote module 12 . For example, the remote computer 201 may update some configuration at the database 21 , request that this be transferred immediately to the remote module 12 , and request that it view the module 12 in real time to see the effect of the configuration changes. This is another significant benefit of centralized decision-making as described above.
[0179] The use of CLI can be extended such that the ISP server 2 may dial any desired remote embedded application at any desired time, in order to initiate a return call from the communications module 12 , to establish a Telnet session followed by a FTP session, generally as described above. Thus, the use of CLI is not just reserved for connecting remote computers 201 , etc to remote module 12 . The remote computer 201 can make changes at the database 21 , for one or more remote modules 12 . The ISP server 2 could then subsequently use CLI to request that the remote modules 12 synchronize immediately, rather than waiting for predetermined dial up times.
[0180] FIG. 39 is a simple flow diagram to illustrate the initial steps in establishing a connection between ISP Server 2 and remote application 1 by use of CLI, as described above.
[0181] In step 61 , a PC (e.g. remote computer 201 ) logs on to the ISP Server 2 , to establish a typical web browsing session. In step 62 , the PC requests the ISP Server 2 to connect to the remote embedded application 1 and, in step 63 , the ISP Server 2 dials up the module 12 using CLI. In step 64 , the module 12 detects the CLI but does not answer the incoming call. After a predetermined time, the module dials back to the ISP Server 2 in step 65 . Thereafter, a file transfer session may be implemented, using techniques as described above, and involving the remote application 1 , ISP Server 2 and, optionally, remote computer such as 201 . Alternatively or additionally, the remote computer such as 201 may be connected directly to the remote embedded application 1 .
[0182] During a synchronization process, a direct communication channel could be opened with the remote embedded application 1 , thereby allowing real time data to be captured from equipment of the remote embedded application 1 , rather than the data as last stored in the local database 11 . One way of providing such a channel is described below.
[0183] FIG. 36 illustrates an advantageous option for providing data transfer between the ISP database 21 and the vending machine database 11 , via their respective controllers 22 and 121 . For simplicity, the modems 23 and 122 are not shown in FIG. 3 and, as is evident from the above description, modems are not invariably required anyway, depending upon the kind of network employed.
[0184] FIG. 36 illustrates schematically the use of TCP ports and sockets (e.g. Telnet) 125 , 126 at the module controller 121 and 225 , 226 at the database controller 22 , to establish separate CONTROL and CLEAR channels. These are similar to the D-channel and B-channel in an ISDN environment. The CONTROL channel provides end-to-end control information between the remote module controller 121 and the database controller 22 , whilst the CLEAR channel is available to exchange pure end-to-end data.
[0185] For example, the remote module controller 121 may connect to the database controller 22 , using the CONTROL channel established between TCP ports and sockets 125 and 225 . A data transfer command or request is transmitted between the database controller 22 and the remote module controller 121 (in either direction) to indicate that it is wished to transfer data from the remote database 11 into a file on the ISP database 21 . If it is not already established, the CLEAR channel is set up between TCP ports and sockets 126 and 226 , and data is them streamed over the CLEAR channel to the database controller 22 , which captures the data in a file in the database 21 . During the data transfer process, the CONTROL channel between TCP ports and sockets 125 and 225 provides end-to-end control—for example, STOP, START, PAUSE, etc; or can provide remote control commands to attached equipment—e.g. PAN/TILT commands whist capturing real compressed video images.
[0186] The above basic mechanism allows the ISP server 2 to act as a kind of “telephone exchange” between remote computers 201 , 202 , etc and remote embedded applications such as 1 which have no direct human control. It may be particularly advantageous when used in conjunction with the CLI ring back procedure that is described above. It may enable higher levels of service to be provided, which may be similar to telephony environments—for example, automatic divert of a TCP/IP session from the database 21 to remote computer 201 , 202 , etc—under the control of decision making at the database server 2 .
[0187] Although the Internet has been given as one very convenient example, it is to be understood that the ISP server 2 may be replaced by any computer network server which effectively is arranged to communicate simultaneously with a plurality of remote computers, whether on a local, large area, national, international, or global network Embodiments of the invention may be used with advantage in environments which include Internet, Extanet, Intranet, and private or public packet switched or circuit switched networks.
[0188] It is to be further appreciated that, in the above described examples, the protocols of Telnet and FTP are just examples or many different kinds of protocols that may be utilized. For example, UDP (User Datagram Protocol) may be utilized as a protocol that is part of the TCP/IP suite of protocols. Instead of Telnet, any file transfer protocol, mechanism or procedure may be used. Instead of FP, one may use any standard or proprietary protocol transferred over a TCP or UDP port or socket.
[0189] In a preferred embodiment, a contractor is hired to service the machine. This contractor can be the same one used to provide other services, such as restocking. Alternatively, a special contractor can be used to service the machines. In still another embodiment, routine service can be provided by one contractor but more serious breakdowns are handled by specialized contractors.
[0190] With respect to the locations of the remote food service, any location away from the consumer's home refrigerator is specifically contemplated. Examples include: campgrounds (private, state and federal), marinas, parks, urban parks, state parks, national parks, picnic areas, sporting grounds, parking lots of sports stadiums, sites for tailgate parties, etc.
SUMMARY OF MAJOR ADVANTAGES OF THE INVENTION
[0191] The remote location of the disclosed food service relieves the traveler of concerns about packing and preserving food for use in outdoor cooking.
[0192] The fully automatic features, including automated sale of the butcher shop food items as well and the off site servicing of the disclosed food service relieve the remote site manager of any significant duties toward managing the food service.
[0193] The categories of food items offered for sale at the remote location will include a significant portion of those food items offered at butcher shops thus providing butcher shop services at a remote location.
[0194] The subject retail shops allow the service to be offered on a round-the-clock basis.
[0195] The automation features also allow a butcher shop to offer its services at remote locations without having to hire on site staff to collect payment and dispense the food item to the customer.
[0196] The automation and data systems allow efficient management of the remote butcher shop through off site monitoring of the status of the remote butcher shop.
[0197] Furthermore, the data systems with their automatic recording systems will free the remote site manager from the need to report on the status of the remote butcher shop.
[0198] Systems that communicate data from the remote site to offsite locations allow for the efficient management of a plurality of remote butcher shops. The plurality of shops are configured to report to managers at a relatively few offsite locations or even to a single manager at a single offsite location.
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A system is described which allows the delivery of butcher shop meat services to a remote location, such as marinas, campsites, parks etc., without significant input required from on site management personnel. Management operations are performed from a remote location. This includes food item selection, preliminary preparation, monitoring of inventories (and re-supply when necessary) and payments. By using this system, managers of remote locations can significantly enhance the ability to meet customers' needs without having to hire or train butcher shop personnel to manage each site.
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